Speedster 200 - Sea-Doo.net

Shop ManualSPEEDSTER 200(TWIN 1503)

Legal deposit:National Library of Quebec4 th trimester 2003National Library of CanadaAll rights reserved. No parts of this manual may be reproduced in anyform without the prior written permission of Bombardier Inc.©Bombardier Inc. 2003Technical PublicationsBombardier Inc.Valcourt (Quebec) CanadaPrinted in Canada®*Registered trademarks of Bombardier Inc.Loctite ® is a trademark of Loctite CorporationSnap-on ® is a trademark of Snap-on Tools CorporationGelcote ® is a trademark of Gelcote International Limited

TABLE OF CONTENTSSECTION SUBSECTION PAGESAFETY NOTICE.................................................................................................................................. IIINTRODUCTION ................................................................................................................................... III01 SERVICE TOOLSAND PRODUCTS01 - Table of contents ...................................................................... 01-01-102 - Mandatory service tools............................................................ 01-02-103 - Optional service tools................................................................ 01-03-104 - Service products ....................................................................... 01-04-102 MAINTENANCE 01 - Table of contents ...................................................................... 02-01-102 - Periodic inspection chart........................................................... 02-02-103 - Flushing and lubrication............................................................. 02-03-104 - Water-flooded engine................................................................ 02-04-105 - Storage...................................................................................... 02-05-103 TROUBLESHOOTING 01 - Troubleshooting chart ............................................................... 03-01-104 ENGINE (4-TEC) 01 - Table of contents ...................................................................... 04-01-102 - Leak test ................................................................................... 04-02-103 - Intake system............................................................................ 04-03-104 - Exhaust system......................................................................... 04-04-105 - Removal and installation ........................................................... 04-05-106 - PTO housing/Magneto .............................................................. 04-06-107 - Lubrication system.................................................................... 04-07-108 - Cylinder head and valves........................................................... 04-08-109 - Engine block.............................................................................. 04-09-105 ENGINEMANAGEMENT(4-TEC)01 - Table of contents ...................................................................... 05-01-102 - Overview................................................................................... 05-02-103 - Component inspection and adjustment .................................... 05-03-104 - Diagnostic procedures .............................................................. 05-04-106 COOLING SYSTEM 01 - Table of contents ...................................................................... 06-01-102 - Circuit, components and care ................................................... 06-02-107 FUEL SYSTEM 01 - Table of contents ...................................................................... 07-01-102 - Fuel circuit................................................................................. 07-02-103 - Air intake ................................................................................... 07-03-108 ELECTRICALSYSTEM09 PROPULSIONSYSTEM10 STEERINGSYSTEM01 - Table of contents ...................................................................... 08-01-102 - Charging system ....................................................................... 08-02-103 - Starting system ......................................................................... 08-03-104 - Instruments and accessories .................................................... 08-04-101 - Table of contents ...................................................................... 09-01-102 - Jet pump................................................................................... 09-02-103 - Drive system............................................................................. 09-03-101 - Table of contents ...................................................................... 10-01-102 - Steering system........................................................................ 10-02-103 - Alignment.................................................................................. 10-03-104 -Throttle/Shifter controller ........................................................... 10-04-111 HULL/DECK 01 - Table of contents ...................................................................... 11-01-102 - Components.............................................................................. 11-02-103 - Repair........................................................................................ 11-03-112 TECHNICAL DATA 01 - Speedster 200........................................................................... 12-01-113 WIRING DIAGRAMS 01 - Wiring diagrams ........................................................................ 13-01-1LMR2004_001_002A.FMI

SAFETY NOTICESAFETY NOTICEThis manual has been prepared as a guide to correctly service and repair the SEA-DOO Speedster200 sport boat.This edition was primarily published to be used by sport boat mechanical technicians who are alreadyfamiliar with all service procedures relating to Bombardier made sport boats. Mechanical techniciansshould attend training courses given by the Bombardier Training Dept.Please note that the instructions will apply only if proper hand tools and special service tools are used.This Shop Manual uses technical terms which may be slightly different from the ones used in the PartsCatalog.It is understood that this manual may be translated into another language. In the event of any discrepancy,the english version shall prevail.The content depicts parts and/or procedures applicable to the particular product at time of writing. Serviceand Warranty Bulletins may be published to update the content of this manual. Make sure to read andunderstand these.In addition, the sole purpose of the illustrations throughout the manual, is to assist identification of thegeneral configuration of the parts. They are not to be interpreted as technical drawings or exact replicasof the parts.The use of Bombardier parts is most strongly recommended when considering replacement of any component.Dealer and/or distributor assistance should be sought in case of doubt.The engines and the corresponding components identified in this document should not be utilized onproduct(s) other than those mentioned in this document.Torque wrench tightening specifications must be strictly adhered to. Locking devices (ex.: locking tab,self-locking fasteners, etc.) must be installed or replaced with new ones. If the efficiency of a lockingdevice is impaired, it must be renewed.This manual emphasizes particular information denoted by the wording and symbols: WARNINGIdentifies an instruction which, if not followed, could cause serious personal injury includingpossibility of death.CAUTION: Denotes an instruction which, if not followed, could severely damage vehicle components.NOTE: Indicates supplementary information needed to fully complete an instruction.Although the mere reading of such information does not eliminate the hazard, your understanding of theinformation will promote its correct use. Always use common shop safety practice.Bombardier Inc. disclaims liability for all damages and/or injuries resulting from the improper use of thecontents. We strongly recommend that any services be carried out and/or verified by a highly skilledprofessional mechanic. It is understood that certain modifications may render use of the vehicle illegalunder existing federal, provincial and state regulations.IILMR2004_001_002A.FM

INTRODUCTIONINTRODUCTIONThis Shop Manual covers the following Bombardiermade Sea-Doo ® sport boat model.MODELSSpeedster 200ENGINETYPETwin 15034-TECMODELNUMBER5773/5160ENGINE IDENTIFICATIONNUMBER (E.I.N.)1503 EngineThe engine identification number is located at frontof engine.HULL IDENTIFICATION NUMBER(H.I.N.)It is located at the rear of sport boat.Speedster 200F09D0UA11. Engine Identification Number (E.I.N.)F13A04A1. Hull Identification Number (H.I.N.)Refer to the next illustration for a description of theSerial Number.A B C 1 2 3 4 5 L 4 9 5Serialnumber*Identification codeF00A2PA* A letter may also be used as a digit.1Model yearYear of productionMonth of productionARRANGEMENT OF THISMANUALThe manual is divided into 13 major sections:01 SERVICE TOOLS AND PRODUCTS02 MAINTENANCE03 TROUBLESHOOTING04 ENGINE (4-TEC)05 ENGINE MANAGEMENT (4-TEC)06 COOLING SYSTEM07 FUEL SYSTEM08 ELECTRICAL SYSTEM09 PROPULSION SYSTEM10 STEERING SYSTEM11 HULL/DECK12 TECHNICAL DATA13 WIRING DIAGRAMSSeveral sections are divided in various subsections.There is a table of contents at the beginningof many sections.LMR2004_001_002A.FMIII

INTRODUCTIONTYPICAL PAGEPage headingindicates sectionand subsectiondetailed.Subsection titleindicatesbeginning of thesubsection.Subsection 04(MAGNETO SYSTEM)Italic sub-titleabove explodedview indicatepertaining models.Drop representsa liquid productto be applied to asurface. In this caseLoctite 243 toscrew threads.Loctite243Exploded view assitsyou in identifyingparts and relatedpositions.Loctite243Loctite243Loctite243Dotted boxcontains parts ofa particularmodel or anexploded view.Loctite243Bold face numberindicates specialprocedureconcerning this part.Loctite648145 N•m(107 lbf•ft)Anti-seizelubricantIllustration numberfor publishingprocess.F01D4WS03-04-1Page numbering system:03: ENGINE section04: MAGNETO SYSTEM subsection1: First page of this subsectionF01A0CSIVLMR2004_001_002A.FM

INTRODUCTIONTYPICAL PAGESub-title with partname(s) fromexploded view.Section 06 FUEL SYSTEMSubsection 03 (CARBURETORS)Title indicates mainprocedure to becarried-out.Service tool to beused to perform acertain procedure.Title in italic indicates aparticular procedureconcerning a model.CARBURETOR REMOVALTo remove carburetors from engine, proceed as follows:Remove air vent tube support.Unlock retaining slides holding air intake silencer base.Remove air intake silencer base from watercraft.Remove screws holding flame arrester base supportto cylinder head cover.Unscrew base retaining screws then remove base fromcarburetors and move to front of watercraft.Turn the valve to OFF position.NOTE: For fuel line removal, use pliers (P/N 295000 054).Disconnect pulse line from fuel pump.Disconnect fuel fuel supply line from fuel pump.Disconnect fuel return line.Disconnect oil injection pump cable, throttle cable andchoke cable.XP Model OnlyRemove screws no. 6 and lock washers no. 7 retainingcarburetors.DISASSEMBLY AND INSPECTIONInspect parts for corrosion dammage (shaft, butterfly,spring screw, check valve housing, etc.).DiaphragmPUMP DIAPHRAGM LEAK TESTUsing a suitable pump gauge tester, perform the followingtest proceeding as follows:- Install pump gauge tester (P/N 295 000 083) on pulsenipple.- Pump tester until it reaches 28 kPa (4 PSI).1ASub-sub-title incapital indicates aparticular testing,adjustment orrepair procedure.Illustrationalways followstext it ispertained to.Sub-sub-title in thiscase indicates thatparticular procedurefor XP is finished, sofrom this point, allothers models areconcerned.All Others ModelsRemove 4 bolts no. 8 and lock washers no. 12 fromrotary valve cover then move carburetors and rotaryvalve cover on top of engine.NOTE: When removing rotary valve cover , payattention that the rotary valve stay in place, other-wiseit must be timed.Remove carburetors from intake manifold.Disconnect fuel bypass line between carburetors (twincarburetors).Remove carburetor(s) from rotary valve cover.F01F0XBTYPICAL1221 2Diaphragm must stand pressure for 10 seconds. Ifpressure drops, replace diaphragm.“TYPICAL” mentionindicates a generalview which does notrepresent full detail.Numbers in a frameare used to give asequence to beperfomed.Letters are used forany measures.06-03-4Bold numbers in thetext refer to the partsshown in the explodedview at the beginningof the subsection.Numbers are usedfor description ofcomponents.F01A0BSLMR2004_001_002A.FMV

INTRODUCTIONLIST OF ABBREVIATIONS USEDIN THIS MANUALACADCAPSATSB.U.D.S.CAPSCDICPSCSICTSDCDESSDLAE.I.N.ECUEGTEMSEPAHPKSAlternate CurrentDESCRIPTIONAnalog to Digital ConversionAir Pressure SensorAir Temperature SensorBombardier Utility and DiagnosticSoftwareCamshaft Position SensorCapacitor Discharge IgnitionCrankshaft Position SensorCooling System IndicatorCoolant Temperature SensorDirect CurrentDigitally Encoded Security SystemDigital Linear ActuatorEngine Identification NumberElectronic Control UnitExhaust Gas TemperatureEngine Management SystemEnvironmental Protection Agency (USA)Horse PowerKnock SensorMAGMAPSMATSMPHMPIN.A.OPSOPTOSPSP/NPFDPSIPTORPMSTDTBDTDCTOPSTPSVCKVDCWTSDESCRIPTIONMagnetoManifold Air Pressure SensorManifold Air Temperature SensorMile Per HourMulti Protocol InterfaceNot ApplicableOil Pressure SensorOptionalOil Separator Pressure SensorPart NumberPersonal Flotation DevicePound Per Square InchPower Take OffRevolution Per MinuteStandardTo Be DeterminedTop Dead CenterTip-Over Protection SystemThrottle Position SensorVehicle Communication KitVolt Direct CurrentWater Temperature SensorVILMR2004_001_002A.FM

INTRODUCTIONGENERAL INFORMATIONIn the marine industry, PORT, STARBOARD, BOWand STERN are used to refer to LEFT, RIGHT,FRONT and REAR respectively. They always referto the operator’s position sitting in boat.F04L03C4TYPICAL1. BOW (front)2. STARBOARD (RH)3. STERN (rear)4. PORT (LH)The information and component/system descriptionscontained in this manual are correct at timeof writing. Bombardier Inc. however, maintains apolicy of continuous improvement of its productswithout imposing upon itself any obligation to installthem on products previously manufactured.Because of our ongoing commitment to productquality and innovation, Bombardier Inc. reservesthe right at any time to discontinue or changespecifications, designs, features, models or equipmentwithout incurring obligation.This Shop Manual uses technical terms whichmay be different from the ones in the Parts Catalogs.When ordering parts always refer to the specificmodel Parts Catalogs.LMR2004_001_002A.FM132ILLUSTRATIONS ANDPROCEDURESThe illustrations show the typical construction ofthe different assemblies and, in all cases, may notreproduce the full detail or exact shape of the partsshown, however, they represent parts which havethe same or a similar function.CAUTION: These sport boat are designed withparts dimensioned mostly in the metric system.However some components may be fromthe imperial system. When replacing fasteners,make sure to use only those recommended byBombardier.As many of the procedures in this manual are interrelated,we suggest that before undertakingany task, you read and thoroughly understand theentire section or subsection in which the procedureis contained.A number of procedures throughout the book requirethe use of special tools. Before undertakingany procedure, be sure that you have on hand allthe tools required, or approved equivalents.ENGINE EMISSIONSINFORMATIONManufacturer’s ResponsibilityBeginning with 1999 model year engines, sportboat manufacturers of marine engines must determinethe exhaust emission levels for each enginehorsepower family and certify these engines withthe United States of America Environmental ProtectionAgency (EPA). An emissions control informationlabel, showing emission levels and enginespecifications, must be placed on each vehicle atthe time of manufacture.Dealer ResponsibilityWhen performing service on any 1999 and newerSea-Doo sport boat carrying an emissions controlinformation label, adjustments must be kept withinpublished factory specifications.Replacement or repair of any emission relatedcomponent must be executed in a manner thatmaintains emission levels within the prescribedcertification standards.Dealers are not to modify the engine in any mannerthat would alter the horsepower or allow emissionlevels to exceed their predetermined factoryspecifications.VII

INTRODUCTIONExceptions include manufacturer’s prescribedchanges, such as altitude adjustments for example.Owner ResponsibilityThe owner/operator is required to have enginemaintenance performed to maintain emission levelswithin prescribed certification standards.The owner/operator is not to, and should not allowanyone to modify the engine in any manner thatwould alter the horsepower or allow emissionslevels to exceed their predetermined factory specifications.EPA Emission RegulationsAll 1999 and newer Sea-Doo sport boats manufacturedby Bombardier are certified to the EPA asconforming to the requirements of the regulationsfor the control of air pollution from new sport boatengines. This certification is contingent on certainadjustments being set to factory standards. Forthis reason, the factory procedure for servicing theproduct must be strictly followed and, wheneverpracticable, returned to the original intent of thedesign.The responsibilities listed above are general and inno way a complete listing of the rules and regulationspertaining to the EPA requirements on exhaustemissions for marine products. For more detailedinformation on this subject, you may contactthe following locations:SELF-LOCKING FASTENERSPROCEDUREThe following describes the most common applicationprocedures when working with self-lockingfasteners.Use a metal brush or a screw tap to clean the holeproperly then use a solvent (Methyl-Chloride), letact during 30 minutes and wipe off. The solventutilization is to ensure the adhesive works properly.LOCTITE APPLICATIONPROCEDUREThe following describes the most common applicationprocedures when working with Loctiteproducts.NOTE: Always use proper strength Loctite productas recommended in this Shop Manual.THREADLOCKERUncovered Holes (bolts and nuts)1VIA U.S. POSTAL SERVICE:Office of Mobile SourcesEngine Programs and Compliance DivisionEngine Compliance Programs Group (6403J)401 M St. NWWashington, DC 20460VIA EXPRESS or COURIER MAIL:Office of Mobile SourcesEngine Programs and Compliance DivisionEngine Compliance Programs Group (6403J)501 3 rd St. NWWashington, DC 20001EPA INTERNET WEB SITE:http:/www.epa.gov/omswww2A00A3LA1. Apply here2. Do not apply1. Clean threads (bolt and nut) with solvent.2. Apply Loctite Primer N (P/N 293 800 041) onthreads and allow to dry.3. Choose proper strength Loctite threadlocker.4. Fit bolt in the hole.5. Apply a few drops of threadlocker at proposedtightened nut engagement area.6. Position nut and tighten as required.VIIILMR2004_001_002A.FM

INTRODUCTIONBlind HolesA00A3MA1. On threads2. On threads and at the bottom of hole1. Clean threads (bolt and hole) with solvent.2. Apply Loctite Primer N (P/N 293 800 041) onthreads (bolt and nut) and allow to dry for 30seconds.3. Choose proper strength Loctite threadlocker.4. Apply several drops along the threaded hole andat the bottom of the hole.5. Apply several drops on bolt threads.6. Tighten as required.Stud in Blind Holes2A00A5RA21. On threads2. On threads and in the hole3. Onto nut threads11 31. Clean threads (stud and hole) with solvent.2. Apply Loctite Primer N (P/N 293 800 041) onthreads and allow to dry.3. Put several drops of proper strength Loctitethreadlocker on female threads and in hole.4. Apply several drops of proper strength Loctiteon stud threads.5. Install stud.6. Install cover, etc.7. Apply drops of proper strength Loctite on uncoveredthreads.8. Tighten nuts as required.Preassembled Parts2A00A3OA1. Apply here2. Do not apply11. Clean bolts and nuts with solvent.2. Assemble components.3. Tighten nuts.4. Apply drops of proper strength Loctite on bolt/nut contact surfaces.5. Avoid touching metal with tip of flask.NOTE: For preventive maintenance on existingequipment, retighten nuts and apply properstrength Loctite on bolt/nut contact surfaces.LMR2004_001_002A.FMIX

INTRODUCTIONAdjusting ScrewA00A3PA1. Apply here2. Plunger1. Adjust screw to proper setting.2. Apply drops of proper strength Loctite threadlockeron screw/body contact surfaces.3. Avoid touching metal with tip of flask.NOTE: If it is difficult to readjust, heat screw witha soldering iron (232°C (450°F)).STRIPPED THREAD REPAIRStripped Threads2115826Standard Thread Repair1. Follow instructions on Loctite FORM-A-THREAD81668 package.2. If a plate is used to align bolt:a. Apply release agent on mating surfaces.b. Put waxed paper or similar film on the surfaces.3. Twist bolt when inserting it to improve threadconformation.NOTE: NOT intended for engine stud repairs.Repair of Small Holes/Fine ThreadsOption 1: Enlarge damaged hole, then follow STAN-DARD THREAD REPAIR procedure.Option 2: Apply FORM-A-THREAD on the screwand insert in damaged hole.Permanent Stud Installation (light duty)1. Use a stud or thread on desired length.2. DO NOT apply release agent on stud.3. Perform a STANDARD THREAD REPAIR (seeabove).4. Allow to cure for 30 minutes.5. Assemble.GASKET COMPOUNDAll Parts1231A00A3QA471. Release agent2. Stripped threads3. Form-A-Thread4. Tape5. Cleaned bolt6. Plate7. New threads8. ThreadlockerA00A3SA1 31. Proper strength Loctite2. Loctite Primer N (P/N 293 800 041) and Gasket Eliminator 518(P/N 293 800 038) on both sides of gasket3. Loctite Primer N onlyXLMR2004_001_002A.FM

INTRODUCTION1. Remove old gasket and other contaminantswith Loctite Chisel remover (P/N 413 708 500).Use mechanical means if necessary.NOTE: Avoid grinding.2. Clean both mating surfaces with solvent.3. Spray Loctite Primer N on both mating surfacesand on both sides of gasket. Allow to dry 1 or 2minutes.4. Apply GASKET ELIMINATOR 518 (P/N 293 800038) on both sides of gasket, using a clean applicator.5. Place gasket on mating surfaces and assembleimmediately.NOTE: If the cover is bolted to blind holes (above),apply proper strength Loctite in the hole and onthreads. Tighten.If holes are sunken, apply proper strength Loctiteon bolt threads.6. Tighten as usual.3. DO NOT use anti-seize Loctite or any similarproduct.4. No curing period is required.Mounting in Tandem1. Apply retaining compound on internal elementbore.2. Continue to assemble as shown above.CASE-IN COMPONENTSMetallic GasketsMOUNTING ON SHAFTMounting with a PressA00A3VA 11. Proper strength LoctiteA00A3UA1. Bearing2. Proper strength Loctite3. ShaftStandard1. Clean shaft external part and element internalpart.2. Apply a strip of proper strength Loctite on shaftcircumference at insert or engagement point.NOTE: Retaining compound is always forced outwhen applied on shaft.3211. Clean inner housing diameter and outer gasketdiameter.2. Spray housing and gasket with Loctite Primer N(P/N 293 800 041).3. Apply a strip of proper strength Loctite on leadingedge of outer metallic gasket diameter.NOTE: Any Loctite product can be used here. Alow strength liquid is recommended as normalstrength and gap are required.4. Install according to standard procedure.5. Wipe off surplus.6. Allow it to cure for 30 minutes.NOTE: Normally used on worn-out housings toprevent leaking or sliding.It is generally not necessary to remove gasketcompound applied on outer gasket diameter.LMR2004_001_002A.FMXI

INTRODUCTIONTIGHTENING TORQUESTighten fasteners to torque mentioned in explodedviews and text. When they are not specifiedrefer to following table.The table also gives themetric conversion.N•mFASTENER SIZE(8.8 grade)Lbf•in1 92 M4 183 274 M5 355 446 537 628 719 8010 M6 8911 9712 10613 11514 12415 13316 14217 15018 15919 168N•mFASTENER SIZE(8.8 grade)Lbf•ft20 1521 1522 1623 M8 1724 1825 1826 1927 2028 2129 2130 2231 2332 2433 2434 2535 2636 27N•mFASTENER SIZE(8.8 grade)Lbf•ft37 2738 2839 2940 3041 3042 3143 3244 3245 3346 3447 3548 M10 3549 3650 3751 3852 3853 3954 4055 4156 4157 4258 4359 4460 4461 4562 4663 4664 4765 4866 4967 4968 5069 5170 5271 5272 5373 5474 5575 5576 5677 5778 5879 5880 M12 59XIILMR2004_001_002A.FM

INTRODUCTIONN•mFASTENER SIZE(8.8 grade)Lbf•ft81 6082 6083 6184 6285 6386 6387 6488 6589 6690 6691 6792 6893 6994 6995 7096 7197 7298 7299 73100 74101 74102 75103 76104 77105 77106 78107 79108 80109 80110 81111 82112 83113 83114 84115 85N•mFASTENER SIZE(8.8 grade)Lbf•ft116 86117 86118 87119 88120 89121 89122 90123 91124 91125 92126 93127 94128 94129 95130 96131 97132 97133 98134 99135 M14 100136 100137 101138 102139 103140 103141 104142 105143 105144 106145 107146 108147 108148 109149 110150 111TIGHTENING TORQUES FOR 8.8 GRADE BOLTS AND NUTSTechnical PublicationsBombardier Inc.Valcourt (Quebec), CanadaLMR2004_001_002A.FMXIII

Section 01 SERVICE TOOLS AND PRODUCTSSubsection 01 (TABLE OF CONTENTS)TABLE OF CONTENTS 0MANDATORY SERVICE TOOLS ........................................................................................... 01-02-1ENGINE .............................................................................................................................. 01-02-1COOLING/FUEL/OIL SYSTEMS ........................................................................................ 01-02-2PROPULSION SYSTEM..................................................................................................... 01-02-3OPTIONAL SERVICE TOOLS ................................................................................................ 01-03-1ENGINE .............................................................................................................................. 01-03-1COOLING/FUEL/OIL SYSTEMS ........................................................................................ 01-03-3PROPULSION SYSTEM..................................................................................................... 01-03-4SPORT BOAT HANDLING................................................................................................. 01-03-4SERVICE PRODUCTS ............................................................................................................ 01-04-1LMR2004-030_01_01ATOC.FM 01-01-1

Section 01 SERVICE TOOLS AND PRODUCTSSubsection 02 (MANDATORY SERVICE TOOLS)MANDATORY SERVICE TOOLS 0ENGINENEWPiston circlip installerP/N 529 035 765Alignment shaftP/N 295 000 141HandleP/N 420 877 650V04B0B4Starter drive bearing pusherP/N 290 876 502F00B0G4APPLICATIONAll models.NEWAlignment adaptorP/N 529 035 719A00C3V4APPLICATIONUse with pushers (P/N 290 876 609and 290 877 740).Oil pressure gauge (1 to 8 bars)P/N 529 035 709F06B054Alignment support plate kitP/N 529 035 5061) Alignment platesP/N 529 035 5072) SupportP/N 529 035 5113) Screw (2)P/N 207 182 5444) Lock washer (2)P/N 234 181 6015) Flat washer (2)P/N 234 081 410F18B0C4VCK (Vehicle Communication Kit)P/N 529 035 844Individual B.U.D.S. diskettes v1.1P/N 529 035 845Individual CD-RomP/N 529 035 886V00B064Engine oil pressure adapterP/N 529 035 652F00B0F4APPLICATIONAll models.155.6 mm jet pump.F12H0A4APPLICATIONAll models.V00B074LMR2004-002_01_02A.FM 01-02-1

Section 01 SERVICE TOOLS AND PRODUCTSSubsection 02 (MANDATORY SERVICE TOOLS)ENGINE (continued)NEWNEWCrankshaft locking toolP/N 529 035 821Camshaft locking toolP/N 529 035 839F18B074F18B064COOLING/FUEL/OIL SYSTEMSPliersP/N 295 000 070Oetiker 1099Fuel pressure gaugeP/N 529 035 591NEWCoolant pump seal pusherP/N 529 035 823F01D174APPLICATIONAll models.F18B084PliersP/N 295 000 054CaillauF02B0B4NEWOil seal guideP/N 529 035 822F01B1T4APPLICATIONAll models.NOTE: This tool is also used for thepropulsion system.F18B09401-02-2 LMR2004-002_01_02A.FM

Section 01 SERVICE TOOLS AND PRODUCTSSubsection 02 (MANDATORY SERVICE TOOLS)PROPULSION SYSTEMImpeller remover/installerP/N 529 035 820NEWDrive shaft holderP/N 529 035 871NEWShaft pusherP/N 529 035 818F01J0T4PliersP/N 295 000 069Oetiker 1090F18B0G4NEWF01D184APPLICATIONAll models.Drive shaft/floating ringP/N 529 035 841F18B0E4NEWPliersP/N 295 000 054CaillauPressure capP/N 529 035 843F18B044NEWF01B1T4APPLICATIONAll models.NOTE: This tool is also used for thefuel system.Seal/bearing pusherP/N 529 035 819F18B054NEWPTO seal supportP/N 529 035 842F18B0D4F18B0F4LMR2004-002_01_02A.FM 01-02-3

Section 01 SERVICE TOOLS AND PRODUCTSSubsection 03 (OPTIONAL SERVICE TOOLS)OPTIONAL SERVICE TOOLS 0ENGINEDigital/induction typetachometerP/N 529 014 500Protective matP/N 295 000 129NEWDigital multimeterP/N 529 035 868F01B1G4APPLICATIONAll models.F04L1V4APPLICATIONAll models.Terminal (Packard) removerNot sold by BombardierSnap-onTT 600-4F01B1J4APPLICATIONAll models.Safety lanyard switch toolP/N 529 034 600Spring installer/removerP/N 529 035 559A00C3S4NEWExhaust outlet toolP/N 295 000 132V00B0H4APPLICATIONAll models.NEWValve spring compressor clampP/N 529 035 724F01B244APPLICATIONAll models.F01B2A4APPLICATIONAll models.Steering cable toolP/N 295 000 145F01B2P4APPLICATIONAll models.V00B044NEWValve spring compressor cupP/N 529 035 725V04B094LMR2004-002_01_03A.FM 01-03-1

Section 01 SERVICE TOOLS AND PRODUCTSSubsection 03 (OPTIONAL SERVICE TOOLS)ENGINE (continued)NEWRing compressorNot sold by BombardierSnap-on RC980NEWValve stem seal installerP/N 529 035 687Leak test kit pumpP/N 529 021 800V04B084NEWV04B0H4Special pliers for valve stem sealremovalNot sold by BombardierSnap-on YA 8230NEWTorque angle gaugeNot sold by BombardierSnap-on TA362V00B084NEWOil VACP/N 529 035 880V02B064V04B0I4F18B0B401-03-2 LMR2004-002_01_03A.FM

Section 01 SERVICE TOOLS AND PRODUCTSSubsection 03 (OPTIONAL SERVICE TOOLS)COOLING/FUEL/OIL SYSTEMSLighted adjustable mirrorNot sold by BombardierSnap-on50101Hose pincherP/N 295 000 076Flushing adapterP/N 295 500 473F01B1I4APPLICATIONAll models.Hose pincherP/N 529 032 500A01B2I4APPLICATIONAll models.Flexible spout (oil)P/N 414 837 300F00B104APPLICATIONAll models.Use with coupler hose (P/N 295500 258).NEWTest radiator capP/N 295 021 400F04B044F01B234APPLICATIONAll models.APPLICATIONAll models.PASOUVRIRACHAUDF18E1P4LMR2004-002_01_03A.FM 01-03-3

Section 01 SERVICE TOOLS AND PRODUCTSSubsection 03 (OPTIONAL SERVICE TOOLS)PROPULSION SYSTEMHacksawNot sold by BombardierSnap-onHS3F01B1M4APPLICATIONAll models.SPORT BOAT HANDLINGTie-down1.04 m (3 ft 5 in) longP/N 204 990 054F00B014APPLICATIONAll models.01-03-4 LMR2004-002_01_03A.FM

Section 01SERVICE TOOLS AND PRODUCTSSubsection 04 (SERVICE PRODUCTS)SERVICE PRODUCTS 0Loctite ® is a trademark of Loctite Corporation.Permatex ® is a trademark of Loctite Corporation.Dow Corning ® is a trademark of Dow Corning Corporation.Medium strength threadlockerP/N 293 800 060Loctite 243 (blue)(10 mL)High temperature threadlockerP/N 420 899 788Loctite 648 (green)(5 g)Retaining compoundP/N 413 703 100Loctite RC/609 (green)(10 mL)F00A0O4High strength threadlockerP/N 293 800 005Loctite 271 (red)(10 mL)A00B3D4High temperature retainingcompoundP/N 293 800 054Loctite 642(50 mL)A00B2S4General purpose instant adhesiveP/N 293 800 021Loctite 495A00B2V4Gasket eliminatorP/N 293 800 038Loctite 518(50 mL)A00B2U4F00B024F01B124LMR2004-002_01_04A.FM 01-04-1

Section 01 SERVICE TOOLS AND PRODUCTSSubsection 04 (SERVICE PRODUCTS)Flange sealantP/N 293 800 081Loctite 5910(300 mL)SolventP/N 413 711 809Loctite Safety Solvent320 g (11 oz)Pipe sealantA) P/N 293 800 013B) P/N 293 800 018A) Loctite 567 (250 mL)B) Loctite 592 (50 mL)F00B1A4A00B2W4NEWRTV silicone sealantP/N 293 800 066Loctite 5900(300 mL)Hylomar sealantP/N 293 800 001PL-32(100 g)A02B0B4Chisel gasket removerP/N 413 708 500(510 mL)A00B4X4Molykote 111P/N 413 707 000111A00B3F4SealantP/N 293 530 011Sikaflex 221 (black)(350 mL)A00B3W4Primer for gasket eliminatorP/N 293 800 041Loctite 764F01B1D4NEWHigh temperature RTV sealantP/N 293 800 090Ultra Copper(80 mL)A00B574Thread sealantP/N 293 800 050Loctite 577(250 mL)A00B3N4A00B5A4F00B0W401-04-2 LMR2004-002_01_04A.FM

Section 01 SERVICE TOOLS AND PRODUCTSSubsection 04 (SERVICE PRODUCTS)BOMBARDIER storage oilP/N 413 711 600(12 x 350 g)NEWPremixed coolant 50/50-37°C (- 35°F)P/N 293 600 038(16 x 1 L)NEWBOMBARDIER Formula XP-S IIsynthetic injection oilP/N 293 600 245(12 x 1 L)A00B634Sea-Doo fuel stabilizerP/N 413 408 600236 mL (8 oz)A00B5X4Sealant adhesiveP/N 293 800 086Loctite 5150(29647)A00B5T4P/N 293 600 246(3 x 4 L)A00B604A00B5S4A00B5U4P/N 293 600 247(205 L)732 Multi-purpose sealantP/N 293 800 086Dow Corning (90 mL)(clear)F01B1C401-04-4 LMR2004-002_01_04A.FM

Section 01SERVICE TOOLS AND PRODUCTSSubsection 04 (SERVICE PRODUCTS)NEWInstant gasketP/N 293 800 088(7 oz)Sea-Doo CleanerP/N 293 110 001 (400 g)P/N 293 110 002 (4 L)F01B2J4NEWA02B0C4Pulley flange cleanerP/N 413 711 809Jet pump synthetic oilP/N 293 600 011(12 x 6 oz)F01B0P4A00B5V4NEWJet pump greaseP/N 293 550 032(110 g)LMR2004-002_01_04A.FM 01-04-5

Section 02 MAINTENANCESubsection 01 (TABLE OF CONTENTS)TABLE OF CONTENTS 0PERIODIC INSPECTION CHART ........................................................................................... 02-02-1FLUSHING AND LUBRICATION ........................................................................................... 02-03-1GENERAL ........................................................................................................................... 02-03-1WATER-FLOODED ENGINE .................................................................................................. 02-04-1GENERAL ........................................................................................................................... 02-04-1PROCEDURE ...................................................................................................................... 02-04-1STORAGE............................................................................................................................... 02-05-1FUEL SYSTEM ................................................................................................................... 02-05-1ENGINE OIL CHANGE AND FILTER ................................................................................. 02-05-1COOLING SYSTEM FLUSHING AND ENGINE INTERNAL LUBRICATION.................... 02-05-1BATTERY............................................................................................................................ 02-05-2SPORT BOAT CLEANING ................................................................................................. 02-05-2ADDITIONAL RECOMMENDED PROTECTION................................................................ 02-05-2ANTICORROSION TREATMENT....................................................................................... 02-05-2CHECKLIST ........................................................................................................................ 02-05-2LMR2004-030_02_01ATOC.FM 02-01-1

Subsection 02Section 02 MAINTENANCE(PERIODIC INSPECTION CHART)PERIODIC INSPECTION CHART 0The schedule should be adjusted according to operating conditions and use.NOTE: The chart gives an equivalence between number of hours and months/year. Perform the maintenanceoperation to whatever time comes first.IMPORTANT: Schedule for sport boat rental operations or higher number of hour use, will require greaterfrequency of inspection and maintenance.FREQUENCYDESCRIPTIONLMR2004-003_02_02A.FM 02-02-1FIRST10 HOURSEVERY25 HOURS OR3 MONTHSEVERY50 HOURS OR6 MONTHSEVERY100 HOURS OR1 YEARGENERALLubrication/corrosion protection✔ENGINEEngine oil and filter replacement ✔ ✔Support and rubber mount condition/tightness ✔ ✔Condition of seals and fasteners ✔ ✔Exhaust system fasteners ➄ ✔ ✔Spark plug replacement ➄✔COOLING SYSTEMFlushing (exhaust system)✔ ➂Hose and fasteners condition ✔ ✔Coolant replacement➆Coolant expansion tank cap/cooling system pressure test➃FUEL SYSTEMThrottle cable, inspection/lubrication✔Fuel injection system sensors visual inspection ➄ ✔ ✔Throttle body cleaning and inspection. Fault code reading ➄ ➀✔Fuel vent line pressure relief valve inspection✔Fuel lines, connections and fuel system leak test ➄ ✔ ✔Visual inspection: throttle body, sensors, fuel lines, fuel rail and fittings ➄ ✔ ✔Air intake silencer fit/tightness ✔ ✔Fuel tank straps visual inspection ✔ ✔ELECTRICAL SYSTEMCheck fault codes ✔ ✔Electrical connections condition and fastening(ignition system, starting system, fuel injectors etc.)✔✔EMS ECU connectors inspection and lubrication✔ ➀Digitally Encoded Security System and safety lanyard/post condition ✔ ✔Monitoring beeper ✔ ✔Battery condition and fasteners ✔ ✔

Section 02 MAINTENANCESubsection 02 (PERIODIC INSPECTION CHART)DESCRIPTIONSTEERING SYSTEMInspection and cable adjustment ✔ ✔PROPULSION SYSTEMDrive shaft protection boot inspection✔ ➁Grease splines in jet pump✔ ➁Shifter system/cable adjustment ✔ ✔Impeller shaft seal replacement➅Impeller condition and impeller/wear ring clearance✔ ➁Inlet Clearance System (ICS) grate condition✔ ➁Ride plate inspection including coolant leak ✔ ✔HULL AND BODYBilge Pump, check for obstructions ✔ ✔Hull condition ✔ ✔➀ In salt water use.➁ These items have to be initially checked after 25 hours. Thereafter, service as specified in this chart.➂ Daily flushing in salt water or foul water use.➃ Every 200 hours or 2 years.➄ Emission-related component.➅ Replace after the vehicle has completed 100 hours of use, not every year.➆ Replace for storage period.FIRST10 HOURSFREQUENCYEVERY25 HOURS OR3 MONTHSEVERY50 HOURS OR6 MONTHSEVERY100 HOURS OR1 YEAR02-02-2 LMR2004-003_02_02A.FM

Subsection 03Section 02 MAINTENANCE(FLUSHING AND LUBRICATION)FLUSHING AND LUBRICATION 0GENERALNOTE: This procedure to be performed for eachengine.Closed Loop Cooling System4-TEC engines are equipped with a closed loopcooling system which does not need to be flushedeven after salt water use.Open Loop Cooling SystemFlushing the exhaust cooling system with freshwater is essential to neutralize corroding effects ofsalt or other chemical products present in water. Itwill help to remove sand, salt, shells or other particlesin water jackets and/or hoses.Flushing should be performed for each enginewhen the sport boat is not expected to be used furtherthe same day or when the sport boat is stored forany extended time. WARNINGPerform this operation in a well ventilated area.Do not touch any electrical part or jet pumparea when engine is running.Proceed as follows:Clean jet pumps by spraying water into inlets andoutlets and then apply a coating of BOMBARDIERLUBE lubricant or equivalent. WARNINGAlways remove safety lanyard cap from switchto prevent unexpected engine starting beforecleaning the jet pump area. Engine must not berunning for this operation.One engine at a time, connect a garden hose toconnector located at the rear of sport boat on eachjet pump support. WARNINGWhen operating the engine while the sportboat is out of the water, the heat exchanger inthe ride plate may become very hot. Avoid anycontact with ride plate as burns may occur.NOTE: An optional quick connect adapter can beused (P/N 295 500 473). No hose pincher is requiredto flush engines.F07E01C 3 2 1TYPICAL1. Hose adapter2. Quick connect adapter (optional, not mandatory)3. Garden hoseFlushingTo flush the exhaust cooling system, start that enginethen immediately open the water tap. WARNINGCertain components in the engine compartmentmay be very hot. Direct contact may result in skinburn. Do not touch any electrical part or jet pumparea when an engine is running.CAUTION: Never flush a hot engine. Alwaysstart the engine before opening the water tap.Open water tap immediately after engine is startedto prevent overheating.Run the engine about 20 seconds between 4000 -5000 RPM.CAUTION: Never run an engine without supplyingwater to the exhaust cooling system of thatengine when sport boat is out of water.LMR2004-003_02_03A.FM 02-03-1

Section 02 MAINTENANCESubsection 03 (FLUSHING AND LUBRICATION)Ensure water flows out of exhaust outlet whileflushing. Otherwise, refer to an authorized Sea-Doodealer for servicing.CAUTION: Never run engine longer than 5 minutes.Drive line seal has no cooling when watercraftis out of water.Close the water tap, then stop the engine.CAUTION: Always close the water tap beforestopping the engine.NOTE: Engine valves fogging should be done wheneverthe sport boat is to be stored for a long period.Refer to STORAGE section.02-03-2 LMR2004-003_02_03A.FM

Section 02 MAINTENANCESubsection 04 (WATER-FLOODED ENGINE)WATER-FLOODED ENGINE 0GENERALNOTE: This procedure to be performed for eachengine.If an engine becomes water-flooded, it must beserviced within a few hours after the event. Otherwiseengine(s) will have to be overhauled.CAUTION: Each water-flooded engine must beproperly lubricated, operated then lubricatedagain, otherwise parts will be seriously damaged.PROCEDURECheck fuel reservoir for water contamination. Ifnecessary, siphon and refill with fresh fuel.To limit damages to the engine(s), perform the followingprocedure as soon as possible for each engine.Drain bilge if water is present.If it was submerged in salt water, spray bilge andall components with fresh water using a gardenhose to stop the salt corroding effect.CAUTION: Never try to crank or start theengines. Water trapped in the intake manifoldwould enter the combustion chambersthrough the intake valves and may cause damageto the engines.Whenever the engines are stopped, all the valvesclose to prevent water from being ingested in theengines.If water is suspected to be in the intake manifoldsand the exhaust systems, they must be drained asfollows:Remove each intake manifold and suck out thewater from the intake valve ports. Refer to subsectionINTAKE SYSTEM.Remove the water from each engine’s oil/air separatorbreather hose.Remove the exhaust pipes, the mufflers and theresonators and drain them. Refer to subsectionEXHAUST SYSTEM.If water gets in the oil (oil will appear milky),change the engine oil and filter as follows for eachengine:Oil Change ProcedureENGINE WITHOUT THE SCAVENGE OIL PUMPCOVER DRAIN PLUGCAUTION: Never crank or start an engine whensiphon tube is in dipstick hole. Never start anengine when there is no oil in that engine.1. Using the oil VAC (P/N 529 035 880), siphon oilthrough dipstick hole.2. Remove the oil VAC tool from the dip stickhole.3. While in drowned engine mode, crank the enginefor 5 seconds.4. Remove the oil filter cap and the oil filter.5. Again, siphon oil from the reservoir.6. Install a new oil filter and reinstall the oil filtercap.7. Fill up the reservoir with fresh oil.8. Run the engine for 3 minutes in a test tank orconnected to a flush kit9. Repeat the above steps 1 to 7.10. Boil out the remaining water as follows:a. Recommended procedure: BOIL OUT PRO-CEDURE IN A TEST TANK OR TIED TO ATRAILER WITH SPORT BOAT IN WATER.b. Optional procedure: BOIL OUT PROCEDURECONNECTED TO A FLUSH KIT.F18D19A1. Scavenge oil pump cover drain plug1LMR2004_004_02_04A.FM 02-04-1

Section 02 MAINTENANCESubsection 04 (WATER-FLOODED ENGINE)ENGINE WITH THE SCAVENGE OIL PUMPCOVER DRAIN PLUGCAUTION: Never crank or start an engine whensiphon tube is in dipstick hole. Never start anengine when there is no oil in that engine.1. Using the oil VAC (P/N 529 035 880), siphon oilthrough dipstick hole.2. Remove the oil vac tool from the dip stick hole.3. While in drowned engine mode, crank the enginefor 5 seconds.4. Remove the oil filter cap and the oil filter.5. Again, siphon oil from the reservoir.6. Put a rag under the scavenge oil pump cover.7. Remove the scavenge oil pump cover drainplug and install fitting (P/N 293 710 037).8. Connect the oil vac tool Bombardier (P/N 529035 880) to the fitting.9. The front of the engine must be tilted downapproximately 15 degrees to facilitate the removalof the oil. Raise the rear of the boat accordingly.Siphon the oil from the fitting.10. Level the engine.11. Remove the oil vac tool and the fitting. Reinstallthe drain plug.NOTE: Do not forget to install the sealing washeron the drain plug.NOTE: If spillage occurs, clean immediately with thepulley flange cleaner (P/N 413 711 809) to prevent oilstains.12. Install a new oil filter and reinstall the oil filtercap.13. Fill up the reservoir with fresh oil.14. Boil out the remaining water as follows: WARNINGMake sure to safely secure the sport boat beforestarting engine(s).a. Recommended procedure: BOIL OUT PRO-CEDURE WITH SPORT BOAT IN WATER.b. Optional procedure: BOIL OUT PROCEDURECONNECTED TO A FLUSH KIT.A. Boil Out Procedure with Sport Boat in Water1. Run the engine for 5 minutes at 3500 RPM.2. With the engine still running at 3500 RPM, installa hose pincher to the coolant line going tothe oil cooler. WARNINGCertain components in the engine compartmentmay be very hot. Direct contact may resultin skin burn. Do not touch any electricalparts or jet pump area when engine is running.F18E1QA1. Oil cooler coolant inlet hose3. Continue to run the engine at 3500 RPM for 15more minutes (20 minutes total run time).4. Shut the engine off.5. Remove the hose pincher on the coolant linegoing to the oil cooler.CAUTION: Hose pincher should be removedbefore operating the engine. Failure to do thiswill result in damage to the engine.6. Change the oil and filter again.7. Procedure is now completed.B. Boil Out Procedure Connected to a Flush Kit1. On drive shaft, remove the C-clip then move forwardthe ring seal carrier. Refer to DRIVE SYS-TEM section.CAUTION: Make sure that the ring seal carrieris not in contact with the PTO seal assembly,neither with the carbon ring.102-04-2 LMR2004_004_02_04A.FM

Section 02 MAINTENANCESubsection 04 (WATER-FLOODED ENGINE)2. Connect a flush kit to the coolant line.CAUTION: Never run engines without supplyingwater to the exhaust cooling systems whensport boat is out of water.3. Run the engine for 5 minutes at 3000 RPM.4. With the engine still running at 3000 RPM, installa hose pincher to the coolant line going tothe oil cooler. WARNINGCertain components in the engine compartmentmay be very hot. Direct contact may resultin skin burn. Do not touch any electricalparts or jet pump area when engine is running.5. Continue to run the engine at 3000 RPM for 15more minutes (20 minutes total run time).6. Shut off the engine7. Remove the hose pincher on the coolant linegoing to the oil cooler.CAUTION: Hose pinchers should be removedbefore operating the engines. Failure to do thiswill result in damage to the engine(s).8. Change the oil and filter again.9. Move rearward the Ring Seal Carrier and reinstallthe C-clip. Refer to DRIVE SYSTEM section.10. Procedure is now completed.LMR2004_004_02_04A.FM 02-04-3

Section 02 MAINTENANCESubsection 05 (STORAGE)STORAGE 0FUEL SYSTEMVerify fuel system. Check all fuel lines and injectorsfor leaks. Replace damaged hoses or clampsif necessary.CAUTION: Sea-Doo fuel stabilizer (P/N 413 408600) or equivalent should be added in fuel tankprior to engine lubrication to prevent fuel systemcomponents deterioration and protectagainst varnish deposits. Follow manufacturer’sinstructions for proper use.Fill fuel tank completely. Ensure there is no waterinside fuel tank.CAUTION: Should any water be trapped insidefuel tank, severe internal damage may occur tothe fuel injection system. WARNINGFuel is flammable and explosive under certainconditions. Always work in a well ventilatedarea. Do not smoke or allow openflames or sparks in the vicinity. Fuel tank maybe pressurized, slowly turn cap when opening.Never use an open flame to check fuellevel. When fueling, keep sport boat level. Donot overfill or top off the fuel tank and leavesport boat in the sun. As temperature increases,fuel expands and might overflow. Alwaysremove any fuel spillage from the sport boat.ENGINE OIL CHANGE AND FILTERChange the oil and filter for each engine. Refer toLUBRICATION in ENGINE section.COOLING SYSTEM FLUSHINGAND ENGINE INTERNALLUBRICATIONEngine LubricationFogging each engine is recommended at the endof the season and before any extended storageperiod. This will lubricate the intake engine valves,the cylinders and the exhaust valves.To fog the intake engine valves proceed as followsfor each engine:– Remove the two bolts that hold the fuel rail on.– Remove the rail along with the three fuel injectors.– Apply Bombardier Lube lubricant into the intakeports.– Crank engine briefly to prevent fuel injectionand ignition.– Reinstall the injectors.CAUTION: Install new O-rings.– Torque the two bolts that hold the fuel rail on. WARNINGAt preseason preparation, perform a fuelpressure test to ensure there are no leaks.Run engine and check for leaks. Refer to EN-GINE MANAGEMENT section.– Pull engine cover upward to remove it.– Disconnect ignition coil connectors. WARNINGWhen disconnecting coil from spark plug, alwaysdisconnect coil from main harness first.Never check for engine ignition spark from anopen coil and/or spark plug in the enginecompartment as spark may cause fuel vaporto ignite.IMPORTANT: Never cut the locking ties of coilconnectors. This would allow mixing the wires betweencylinders.– Remove ignition coils.CAUTION: Ensure there is no dirt in coil holesbefore removing the spark plugs. Otherwise,dirt will fall into cylinder and damage the internalcomponents.– Remove the spark plugs.– Apply Bombardier Lube lubricant into the cylinders.– Reinstall spark plugs and ignition coils.– Reconnect ignition coil connectors.NOTE: Prior to inserting the ignition coil into itslocation, apply some Bombardier Lube lubricantaround the seal area that touches the spark plughole. After installation, ensure the seal seats properlywith the engine top surface.LMR2004_005_02_05A.FM 02-05-1

Section 02 MAINTENANCESubsection 05 (STORAGE)– To reinstall engine cover, push it downward untilit snaps into position.– Crank engine several times briefly.F18M01A1. Engine intake portsBATTERYFor battery removal, cleaning and storage, refer toCHARGING SYSTEM.SPORT BOAT CLEANINGClean the bilge with hot water and mild detergentor with bilge cleaner. Rinse thoroughly. Lift frontend of sport boat to completely drain bilge. If anyrepairs are needed to body or to the hull, touch uppaint and Gelcote ® repair kits are available. Replacedamaged labels/decals.Wash the body with soap and water solution (onlyuse mild detergent). Rinse thoroughly with freshwater. Remove marine organisms from the hull.Apply a nonabrasive wax.CAUTION: Never clean fiberglass and plasticparts with strong detergent, degreasing agent,paint thinner, acetone, etc.If the sport boat is to be stored outside, cover itwith an opaque tarpaulin to prevent sun rays andgrime from affecting the plastic components,sport boat finish as well as preventing dust accumulation.CAUTION: The sport boat must never be left inwater for storage. Never leave the sport boatstored in direct sunlight.1ADDITIONAL RECOMMENDEDPROTECTIONRefer to the COOLING SYSTEM section.ANTICORROSION TREATMENTRemove any residual water in the engine compartment.Spray Bombardier Lube lubricant over all metalliccomponents in engine compartment.Lubricate the throttle cables with BombardierLube lubricant.The engine compartment lid should be partially leftopened during storage. Remove the engine compartmentstorage tray and store in a safe place.This will avoid engine compartment condensationand possible corrosion.CHECKLISTVerify fuel systemOPERATIONAdd Sea-Doo fuel stabilizerChange oil and filter for each engineFlush each exhaust cooling system byrunning the enginesLubricate each engineRemove, clean and store the batteryClean the bilgeWash the bodyReplace antifreeze for each engine. Checksolution concentration in the cooling system(in cool regions)Spray Bombardier Lube over all metalliccomponents in engine compartment and onthrottle cable✔02-05-2 LMR2004_005_02_05A.FM

Section 03 TROUBLESHOOTINGSubsection 01 (TROUBLESHOOTING CHART)TROUBLESHOOTING CHARTThe following is provided to help in diagnosing the probable source of troubles. It is a guideline and shouldnot be assumed to show all causes for all problems.NOTE: Always check for fault codes recorded in the ECM ECU first using the VCK (vehicle communicationkit (P/N 529 035 844). If a fault code is detected, service the fault code and recheck operating conditions.Refer to DIAGNOSTIC PROCEDURES in ENGINE MANAGEMENT section.ENGINE WILL NOT STARTOTHER OBSERVATION POSSIBLE CAUSE REMEDYEngine does not turn over• Wrong safety lanyard• DESS operation non functional• Safety lanyard switch faulty or disconnectedor harness damaged• Burnt fuse in engine fuseblock, battery,starting system, fuel pump• Starting system fuse keeps on burning• Discharged or disconnected battery• Defective or disconnected start/stopswitch• Battery connections• Water/fuel hydrolock• Starter malfunction• Starter solenoid• Seized or obstructed engine• Seized jet pump• Faulty ECM ECU• Use one that has been programmedfor that sport boat• If 2 short beeps are not heard when installingsafety lanyard, refer to ELEC-TRICAL SYSTEM and ENGINE MAN-AGEMENT• Replace• Check wiring then replace fuse• Check wiring and starting system solenoid• Check/recharge• Check, refer to STARTING SYSTEM orENGINE MANAGEMENT• Check/clean/tighten• Check, refer to MAINTENANCE• Check, refer to ELECTRICAL SYSTEM• Check, refer to ELECTRICAL SYSTEM• Check/repair, refer to ENGINE• Check, refer to PROPULSION SYSTEM• Check faulty codes in ECM ECU memory,refer to ENGINE MANAGEMENTLMR2004_006_03_01A.FM 03-01-1

Section 03 TROUBLESHOOTINGSubsection 01 (TROUBLESHOOTING CHART)ENGINE WILL NOT START (cont’d)OTHER OBSERVATION POSSIBLE CAUSE REMEDYEngine turns slowlyEngine turns overNo spark at spark plugs• Loose battery cable connections• Discharged/weak battery• Restriction in jet pump• Partial seizure in jet pump• Partial engine hydrolock• Partial engine seizure• Worn starter• Outside temperature too low• Low battery voltage• No spark at the spark plug• Defective ECM ECU• Defective crankshaft position sensor• Water-contaminated fuel• Dirty fuel filter• Fouled or defective spark plug• Water in engine• Defective ignition circuit• Internal engine damage• Defective encoder wheel• Insufficient engine compression• Incorrectly aligned flywheel and encoderwheel• Spark plug faulty, fouled or worn out• Ignition• Faulty ECM ECU• Check/clean/tighten• Check/charge/replace• Check/clean pump• Inspect, refer to PROPULSION SYS-TEM• Check, refer to MAINTENANCE• Check compression, refer to ENGINE• Check, refer to ELECTRICAL SYSTEM• Oil is too “thick”. Change oil viscosity• Battery capacity is not sufficient for coldtemperature• Recharge or replace battery• Check spark plugs condition and replaceas necessary• Check ignition system and repair• Replace ECM ECU• Check operation of CPS and replace ifnecessary• Check/siphon and refill• Clean/replace• Replace• Check, refer to MAINTENANCE• Check, refer to ELECTRICAL SYSTEM• Check, refer to ENGINE• Check, refer to ENGINE MANAGEMENT• Replace defective part(s)• Properly position flywheel and encoderwheel, refer to PTO HOUSING/MAGNETO• Check spark plug condition• Check, refer to ELECTRICAL SYSTEM• Replace ECM ECU03-01-2 LMR2004_006_03_01A.FM

Section 03 TROUBLESHOOTINGSubsection 01 (TROUBLESHOOTING CHART)ENGINE HARD TO STARTOTHER OBSERVATION POSSIBLE CAUSE REMEDY• Defective idle bypass valve • Refer to ENGINE MANAGEMENT• Wrong TPS zero setting• Refer to ENGINE MANAGEMENT• Wrong throttle body mechanical adjustmentof cable• Refer to ENGINE MANAGEMENT• Temperature too low for availablebattery capacity• Air lock in fuel rail• Water in intake system(defective sensor)• Water in fuel reservoir or contaminatedfuel• Mechanical engine failure• Spark plug faulty, fouled or worn out• Low fuel pressureENGINE STARTS BUT RUNS ONLY AT IDLE SPEEDENGINE MISFIRES, RUNS IRREGULARLY• Battery capacity is not sufficient for coldtemperature• Refer to ENGINE MANAGEMENT• Check and remove water• Refer to intake system in ENGINE MAN-AGEMENT• Flush reservoir and refill with fresh gas• Check cylinder compression• Check for cylinder head leaks• Check starting system• Check spark plug condition• Check fuel pump operation. Refer to EN-GINE MANAGEMENT• Check fuel pressure regulator. Refer toENGINE MANAGEMENTOTHER OBSERVATION POSSIBLE CAUSE REMEDY• The system is in limp home mode • Refer to ENGINE and check the faultcodes in the ECM ECU• Broken or loose throttle cable • Change/readjustOTHER OBSERVATION POSSIBLE CAUSE REMEDYWeak spark• Fouled, defective, worn spark plugs• Faulty ECM ECU• Defective encoder wheel• Bad ignition coil wiring• Faulty ignition coil, or bad connector• Check/verify heat range/gap/replace• Check, refer to ENGINE MANAGEMENT• Check, refer to ENGINE MANAGEMENT• Check wiring condition and proper groundingof ignition coil• Check coil. Refer to ENGINE MANAGE-MENTLMR2004_006_03_01A.FM 03-01-3

Section 03 TROUBLESHOOTINGSubsection 01 (TROUBLESHOOTING CHART)ENGINE MISFIRES, RUNS IRREGULARLY (cont’d)OTHER OBSERVATION POSSIBLE CAUSE REMEDYLean fuel mixture.Dry spark plug (exceptwhen water fouled)Rich fuel mixture.Fouled spark plugStarts but runs poorlyAlso fuel injectionmalfunction• Low fuel level• Low fuel pressure• Stale or water fouled fuel• Fuel filter dirty or restricted• Clogged fuel injectors• Defective sensor or ECM ECU• Flame arrester dirty or restricted• Faulty fuel injector(s)• Defective sensor or ECM ECU• Fuel pressure fluctuating• High fuel pressure• Check spark plug condition, checkfault codes in the ECM ECU memory,check fuel pressure• Bent or missing tooth on encoderwheel• Injector wiring reversed• Check/refill• Check pump, regulator, injectors andhose pinchers or if filter is plugged. Replaceif necessary• Check/siphon and refill• Check/clean/replace• Remove and clean fuel injectors• Check faulty codes in ECM ECU memory,refer to ENGINE MANAGEMENT• Check/replace• Remove and replace fuel injector(s), referto ENGINE MANAGEMENT• Check fault codes in ECM ECU memory,refer to ENGINE MANAGEMENT• Inspect fuel pressure regulators. Referto ENGINE MANAGEMENT• Check pump, regulator, injectors, hosepinchers or if filter is plugged. Replaceif necessary• Check, refer to ENGINE MANAGEMENT.If some work has been performed onthe unit, make sure injector wire connectorswere not mixed. Refer to thewiring diagram for wire colors and positions• Check, refer to ENGINE MANAGEMENTunder component inspection and adjustment• Check with wiring diagram• Damaged fuel injector• Check, refer to ENGINE MANAGEMENT03-01-4 LMR2004_006_03_01A.FM

Section 03 TROUBLESHOOTINGSubsection 01 (TROUBLESHOOTING CHART)ENGINE CONTINUALLY BACKFIRESOTHER OBSERVATION POSSIBLE CAUSE REMEDYWeak spark • Fouled, defective spark plugs • Clean/replaceSpark plugs • Ignition coil leads or wiring reversed • Check with wiring diagramIgnition timing/TDC setting • Defective encoder wheel • Check, refer to ENGINE MANAGEMENTEngine • Intake or exhaust valve(s) leak • Pressure check engine, refer to ENGINEENGINE DETONATION OR PINGINGOTHER OBSERVATION POSSIBLE CAUSE REMEDYIgnitionEngine/exhaust hightemperature• Timing too far advanced• Spark plug heat range too high• Engine overheats and exhaust overheats• Fuel octane too low/of poor quality• KS disconnected or faulty• Bad KS connection• Bad Kostal connection (on engine)ENGINE LACKS ACCELERATION OR POWER• Check/reset• Check/change to correct range• Check, see engine overheats• Use good quality fuel• Check, refer to ENGINE MANAGEMENT• Check, refer to ENGINE MANAGEMENT• Check, refer to ENGINE MANAGEMENTOTHER OBSERVATION POSSIBLE CAUSE REMEDY• Weak spark• Check/replace, refer to ELECTRICALSYSTEM• Throttle does not open fully• Check/readjust, refer to ENGINE MAN-AGEMENT• Low compression• Check/repair, refer to ENGINE• Water in fuel• Check/siphon/replace• Impeller leading edge damaged • Check/replace, refer to PROPULSIONSYSTEM• Too much engine oil• Siphon or adjust level. Refer to LUBRI-CATION• Poor fuel quality• Siphon then refill with fresh fuel• Clogged fuel injectors• Remove and clean fuel injectors• Low fuel pressure• Check fuel line and fuel pump pressureEngine revs lower thanits maximum operationalRPM• Incorrect throttle position sensor (TPS)adjustment• Improper timing chain alignment• Overheated engine• Limp home mode activated• Check and adjust TPS, refer to ENGINEMANAGEMENT• Refer to CYLINDER HEAD• See ENGINE OVERHEATS in this chart• Refer to ENGINE MANAGEMENTLMR2004_006_03_01A.FM 03-01-5

Section 03 TROUBLESHOOTINGSubsection 01 (TROUBLESHOOTING CHART)ENGINE STOPS RUNNINGOTHER OBSERVATION POSSIBLE CAUSE REMEDY• Spark plug heat range too high • Check/change to correct rangeEngine dies during regular• Compression ratio is too high • Install genuine partsoperation (piston seizure)• Poor oil quality• Use proper BOMBARDIER oilEngine stalls at idle • Air in fuel rail • Refill fuel tankEngine starts but stopsafter approximately2 seconds• Engine running out of fuel• Air in fuel railENGINE CANNOT REACH MAXIMUM RPMENGINE RUNS TOO FAST (vehicle cannot reach its top speed)• Refill fuel tank• Check fuel delivery system for properfuel pressure and deliveryOTHER OBSERVATION POSSIBLE CAUSE REMEDY• The system is in limp home mode. • Refer to ENGINE and check the faultcodes in the ECM ECU• Low fuel pressure• Check fuel pump pressure output• Jet pump related problem• Check propulsion components. Referto JET PUMP• Limp home mode activated• Refer to ENGINE MANAGEMENT• Exhaust gases in bilge (leak) • Check exhaust system for leaksOTHER OBSERVATION POSSIBLE CAUSE REMEDYEngine RPM too highJet pump cavitation• Faulty rev limiter in ECM ECU• Improper impeller pitch (too low)• Incorrect throttle position sensor (TPS)adjustment• Damaged impeller• Damaged leading or trailing edge ofimpeller• Sealing of ride plate, jet pump supportor jet pump• Check, refer to ENGINEMANAGEMENT• Check/replace, refer to PROPULSIONSYSTEM• Check and adjust TPS, refer to ENGINEMANAGEMENT• Replace impeller. Refer to PROPULSION• Check/replaceNOTE: Leading edge damage contributesto poor performance from start. Trailingedge damage contributes to poor top performanceand stator vanes erosion.• Check/reseal, refer to PROPULSIONSYSTEM or HULL/BODY03-01-6 LMR2004_006_03_01A.FM

Section 03 TROUBLESHOOTINGSubsection 01 (TROUBLESHOOTING CHART)ENGINE OVERHEATSOTHER OBSERVATION POSSIBLE CAUSE REMEDYCoolant level too lowMonitoring beeper soundscontinuouslyENGINE SMOKE IN THE EXHAUSTLOW OR NO ENGINE OIL PRESSURE• Coolant level low• Water leaking out of weep hole (PTOhousing)• Hoses or clamps missing/defect• Cylinder head gasket leaks (white exhaustgas)• Temperature sensor defect• Worn water pump impeller• Cooling system restriction• Damaged ride plate or hoses• Thermostat defective• Refill/check for leaks• Replace rotary seal• Repair/replace• Replace cylinder head gasket• Check/replace. Refer to ENGINE MAN-AGEMENT• Check/replace• Check/flush, refer to MAINTENANCE• Check, refer to COOLING SYSTEM andHULL/BODY• Check/replaceOTHER OBSERVATION POSSIBLE CAUSE REMEDYWhite smokeBlue smoke• at engine starting• with engine under load• Coolant leak• Damaged head gasket• Water ingestion• Valve guide seals• Oil rings worn out• Oil rings• Oil level too high• Check/repair. Refer to LEAK TEST• Check/replace the head gasket• Inspect the intake manifold for thepresence of water• Check/replace valve guide seals, referto CYLINDER HEAD AND VALVES• Replace rings• Inspect/repair oil rings, refer to ENGINEBLOCK• Siphon some oil from the oil tankOTHER OBSERVATION POSSIBLE CAUSE REMEDY• Oil level too low• Refill. See TECHNICAL DATA for specifications• Leaking gasket• Replace• Oil leaking out of weep hole• Replace oil seal on pump shaft(PTO housing)• Oil pressure sensor defective • Check/replace• Oil pump malfunctioning• Clean rotor and check wear limits• Oil regulator valve sticks open, or • Clean/replacespring load to small• Heavy wear on plain bearings • ReplaceLMR2004_006_03_01A.FM 03-01-7

Section 03 TROUBLESHOOTINGSubsection 01 (TROUBLESHOOTING CHART)ENGINE OIL CONTAMINATION (WHITE APPEARANCE)OTHER OBSERVATION POSSIBLE CAUSE REMEDYWater and oil mixtureleaking out of weep hole(PTO housing)• Oil seal and rotary seal on water pumpshaft leaking• Cylinder head gasket leaking• Loose screws on cylinder head, PTOhousing or oil separator• Oil contamination due to metal orplastic particles• Water ingestion (intake manifold,TOPS valve, dipstick)UNUSUAL ENGINE NOISE AND/OR VIBRATIONABNORMAL NOISE FROM PROPULSION SYSTEM• Replace both seals. Refer to PTO HOUS-ING. Change oil• Replace gasket. Refer to CYLINDERHEAD. Change oil• Retorque. Change oil• Replace possibly damaged parts.Change oil• Refer to MAINTENANCEOTHER OBSERVATION POSSIBLE CAUSE REMEDY• Worn chain tensioner• Replace• Worn chain guide• Replace• Stretched chain and/or worn out sprockets• Replace chain and sprockets• Sprocket screws got loose• Retorque• Hydraulic element inside rocker arm(s) • Replace faulty rocker arm(s)is (are) worn out (valve adjustment)• Rocker arm screws not tightened • Retorque• Heavy wear on crankshaft and/or balancer• Replaceshaft bearings• Crankshaft and balancer shaft not • Check marks and readjust shaftsaligned• Heavy wear on thrust washers, or • Check/replacethrust washers missingOTHER OBSERVATION POSSIBLE CAUSE REMEDY• Weeds/debris caught in intake grate • Check/cleanor impeller• Damaged or bent drive shaft • Check/replace, refer to PROPULSIONSYSTEM• Idle speed too low• Check fault codes• Broken engine mounts• Check/replace, refer to ENGINENOTE: Prior to replacing a ECM ECU, refer to the appropriate ECM ECU section or ECM ECU REPLACE-MENT in the ENGINE MANAGEMENT section and read carefully the tests to do before replacing a ECMECU that could otherwise be good.03-01-8 LMR2004_006_03_01A.FM

Section 04 ENGINE (4-TEC)Subsection 01 (TABLE OF CONTENTS)TABLE OF CONTENTS 0LEAK TEST............................................................................................................................. 04-02-1LEAK TEST PROCEDURE .................................................................................................. 04-02-1PREPARATION................................................................................................................... 04-02-1PROCEDURE ...................................................................................................................... 04-02-2INSTALLATION.................................................................................................................. 04-02-3INTAKE SYSTEM ................................................................................................................... 04-03-1REMOVAL........................................................................................................................... 04-03-2ASSEMBLY......................................................................................................................... 04-03-5EXHAUST SYSTEM............................................................................................................... 04-04-1EXHAUST PIPE .................................................................................................................. 04-04-3EXHAUST MANIFOLD ...................................................................................................... 04-04-5MUFFLERS (port engine).................................................................................................. 04-04-6MUFFLERS (starboard engine) ........................................................................................ 04-04-7EXHAUST OUTLET (port and starboard) ........................................................................ 04-04-8REMOVAL AND INSTALLATION.......................................................................................... 04-05-1GENERAL ........................................................................................................................... 04-05-1ENGINE REMOVAL............................................................................................................ 04-05-1CLEANING ......................................................................................................................... 04-05-2INSTALLATION .................................................................................................................. 04-05-2PTO HOUSING/MAGNETO .................................................................................................. 04-06-1GENERAL ........................................................................................................................... 04-06-2PTO HOUSING................................................................................................................... 04-06-2PTO SEAL........................................................................................................................... 04-06-5COUPLING ......................................................................................................................... 04-06-5STATOR ............................................................................................................................. 04-06-6ROTOR AND ENCODER WHEEL....................................................................................... 04-06-7RING GEAR ........................................................................................................................ 04-06-7STARTER DRIVE ASS’Y .................................................................................................... 04-06-8LMR2004-030_04_01ATOC.FM 04-01-1

Section 04 ENGINE (4-TEC)Subsection 01 (TABLE OF CONTENTS)LUBRICATION SYSTEM......................................................................................................... 04-07-1GENERAL............................................................................................................................ 04-07-3OIL LEVEL VERIFICATION ................................................................................................. 04-07-3ENGINE PRESSURE TEST ................................................................................................. 04-07-3OIL FILTER .......................................................................................................................... 04-07-6OIL STRAINERS.................................................................................................................. 04-07-6ENGINE OIL PRESSURE REGULATOR............................................................................. 04-07-9OIL PRESSURE PUMP ....................................................................................................... 04-07-10OIL SUCTION PUMP .......................................................................................................... 04-07-13OIL FILTER BYPASS........................................................................................................... 04-07-15OIL COOLER ....................................................................................................................... 04-07-16OIL SEPARATOR ................................................................................................................ 04-07-17CYLINDER HEAD AND VALVES ........................................................................................... 04-08-1GENERAL............................................................................................................................ 04-08-2SPARK PLUG...................................................................................................................... 04-08-2VALVE COVER .................................................................................................................... 04-08-3ROCKER ARM..................................................................................................................... 04-08-3CAMSHAFT TIMING GEAR................................................................................................ 04-08-7TIMING CHAIN ................................................................................................................... 04-08-8CYLINDER HEAD ................................................................................................................ 04-08-8CAMSHAFT......................................................................................................................... 04-08-10VALVE SPRING................................................................................................................... 04-08-11VALVE ................................................................................................................................. 04-08-12ENGINE BLOCK...................................................................................................................... 04-09-1GENERAL............................................................................................................................ 04-09-3CRANKSHAFT LOCKING ................................................................................................... 04-09-3CRANKSHAFT .................................................................................................................... 04-09-3TIMING CHAIN ................................................................................................................... 04-09-8CHAIN TENSIONER............................................................................................................ 04-09-8BALANCER SHAFT............................................................................................................. 04-09-8ENGINE BLOCK.................................................................................................................. 04-09-11PISTON/CONNECTING ROD ............................................................................................. 04-09-16PISTON RINGS ................................................................................................................... 04-09-2104-01-2 LMR2004-030_04_01ATOC.FM

Section 04 ENGINE (4-TEC)Subsection 02 (LEAK TEST)LEAK TEST 0LEAK TEST PROCEDURENOTE: This procedure to be performed for eachengine.This procedure has to be done when engine operatingtemperature of approx. 70°C (158°F) is reached. WARNINGPrevent burning yourself while handling thehot engine.1PREPARATIONRemove:– safety lanyard WARNINGSafety lanyard must be removed to preventengine from being cranked while fuel rail is removedin order to prevent fuel being sprayedout. Fuel is flammable.– fuel rail cover, then remove fuel rail retainingscrews and move away just enough to see theinjection holes– exhaust pipe (refer to EXHAUST SYSTEM)– drive shaft(refer to JET PUMP in PROPULSION SYSTEM)– coolant tank cap WARNINGTo prevent burning yourself, only remove thecoolant tank cap by wearing the appropriatesafety equipment.R1503motr153A1. Oil dipstick– unplug ignition coils and remove– spark plugs from cylinder head.CAUTION: Ensure there is no dirt in coil holesbefore removing the spark plugs. Otherwise,dirt will fall into cylinder and damage the internalcomponents.NOTE: Ignition coil may be used as an extractor forspark plugs.21– oil dipstickR1503motr154A1. Ignition coil2. Spark plugLMR2004_007_04_02A.FM 04-02-1

Section 04 ENGINE (4-TEC)Subsection 02 (LEAK TEST)– Remove valve cover cowl.– Unscrew and remove valve cover.2 1Hold the crankshaft in this position by using theimpeller remover/installer tool (P/N 529 035 820)and a wrench.Install gauge adapter into previously cleaned sparkplug hole.Connect to adequate air supply.NOTE: Each tester will have specific instructionson gauge operation and required pressure.Set needle of measuring gauge to zero.Supply combustion chamber with air.1R1503motr155A1. Valve cover2. Valve cover screwPROCEDURENOTE: The following procedure must be performedfor each cylinder separately, because of the 120°offset between the TDCs.Rotate crankshaft until all valves are closed by usingPTO flywheel remover/installer (P/N 529 035 820).Therefore you have to monitor the rocker arms.R1503motr156A13R1503motr157A1. Measuring gauge2. Adequate adapter for spark plug hole3. Air supplyNote the amount of leaking or percentage (dependingon tester).LEAKAGEPERCENTAGEENGINECONDITION0% to 7% Excellent condition.8% to 15%16% to 30%30% and higherFair condition; proceed withtune up or adjustment.Poor condition; engine will runand performance might bedown in some cases.Very poor condition, diagnoseand repair engine.21. Intake rocker armsRotate the crankshaft counterclockwise until theintake rocker arm has performed a full stroke.Then rotate crankshaft for another half turn to besure that the valves are closed.04-02-2 LMR2004_007_04_02A.FM

Section 04 ENGINE (4-TEC)Subsection 02 (LEAK TEST)DiagnosePressurize area to be tested, spray soap/water solutionat the indicated location and look and/or listenfor air bubbles.– air escaping on intake port means leaking intakevalve(s)– air escaping on exhaust port means leaking exhaustvalve(s)– air bubbles out of coolant tank means leakingcylinder head gasket– air escaping into crankcase area means excessivelyworn and/or broken piston rings.INSTALLATIONNOTE: For installation use the torque values andLoctite products from the exploded views (refer toproper engine subsection).For installation, reverse the preparation procedure.NOTE: Prior to inserting the ignition coil to its location,apply some BOMBARDIER LUBE lubricantaround the seal area that touches the sparkplug hole. After installation, ensure the seal seatsproperly with the engine top surface.General Engine LeakageSpray soap/water solution at the indicated locationand look and/or listen for air bubbles.Pay attention to the following checkpoints:– clamp(s) tightened– coolant hoses– air/oil escaping from crankcase means damagedgasket(s) and/or loosened screws(refer to ENGINE BLOCK)– air/water escaping from cylinder/head meansdamaged gasket(s) and/or loosened screws(refer to CYLINDER HEAD AND VALVES)– oily contamination on weep hole (speed sensorarea) means a damaged oil seal on coolant pumpshaft– coolant out of weep hole means a damaged rotaryseal on coolant pump shaft(refer to COOLING SYSTEM)R1503motr158A1. Weep hole– coolant escaping from coolant pump housingmeans damaged gasket(s) and/or loosenedscrews (refer to COOLING SYSTEM).NOTE: For all the checkpoints mentioned abovesee the appropriate engine section to diagnoseand repair the engine.1LMR2004_007_04_02A.FM 04-02-3

Section 04Subsection 03ENGINE (4-TEC)(INTAKE SYSTEM)INTAKE SYSTEM 0Loctite 24310 N•m(89 lbf•in)Loctite 2436 N•m(53 lbf•in)10 N•m(89 lbf•in)OilLoctite 243Loctite 24310 N•m(89 lbf•in)Loctite 2436 N•m(53 lbf•in)18 N•m(159 lbf•in)10 N•m(89 lbf•in)R1503motr63SLMR2004_008_04_03A.FM 04-03-1

Section 04 ENGINE (4-TEC)Subsection 03 (INTAKE SYSTEM)REMOVALAir Intake ManifoldNOTE: This procedure to be performed for eachengine.Remove oil dipstick.Pull fuel rail cover out.Disconnect battery cables from battery. WARNINGAlways disconnect battery cables exactly inthe specified order, BLACK negative cablefirst then the RED positive battery cable last.Release the fuel pressure in the system, refer toENGINE MANAGEMENT section.Disconnect fuel hose connector at fuel rail.Cut locking ties where shown.1F18D0CA1. Cut locking tiesUnplug connectors from ignition coils, TOPS valve,OSPS, TPS, idle bypass valve, engine connector,CTS, CAPS, KS, CPS, magneto, OPS and EGT.12112 3 101298761 1R1503motr60A54R1503motr78AStep 1 : SqueezeStep 2 : Pull out1. Supporting tabs2. Squeeze in middle of supporting tabs, hold and pull out1.Ignition coils2.TOPS3.TPS (hidden behind throttle body)4.Idle bypass valve5.Engine connector6.KS7.CPS8.Magneto9.“B” Kostal connector10.OSPS04-03-2 LMR2004_008_04_03A.FM

Section 04Subsection 03ENGINE (4-TEC)(INTAKE SYSTEM)For the TOPS valve connector, refer to the followingillustration.1R1503motr64A11. CTS connectorR1503motr69A1. Push here and hold while pulling connector outNOTE: The TPS connector is hidden behind theTOPS hose. Disconnect hose from TOPS valvethen move away to access the TPS connector.Slightly pry locking tab of connector to unlock.1R1503motr65A11. CAPS connector23R1503motr75A1. TOPS hose disconnected and moved away2. TPS connector3. Slightly pry tab to unlockR1503motr66A1. EGT connector1LMR2004_008_04_03A.FM 04-03-3

Section 04 ENGINE (4-TEC)Subsection 03 (INTAKE SYSTEM)Pull the connectors for KS, CPS and magneto outof the ECU support.Pull wiring harness away from intake manifold.Slacken air intake silencer collar.Unlock throttle cable housing from throttle body.Cable is to be detached further.2F18D0BA 1211. Oil filter housing2. OPSUnplug the “B” Kostal connector from the EngineECU.R1503motr72A1. Air intake silencer collar2. Unlock throttle cable housingRemove 7 retaining screws and push the oil dipsticktube out of the manifold slot.R1503motr70A11. Push this end to unlockR1503motr59A1R1503motr71A1. Pull here to release04-03-4 LMR2004_008_04_03A.FM

Section 04Subsection 03ENGINE (4-TEC)(INTAKE SYSTEM)Lift intake manifold up to pull it out of the mountingbrackets just enough to reach throttle cableend.R1503motr274AR1503motr61A1. Mounting brackets1Detach throttle cable end from throttle body.TYPICALNOTE: The flame arrester in intake manifold ismaintenance free.ASSEMBLYAssembly is essentially the reverse of removalprocedures. However pay particular attention tothe following.CAUTION: Do not modify air intake system,otherwise calibration will be affected.Air Intake ManifoldEnsure that all gaskets are properly installed andin a good condition.R1503motr76A11. Detach cable end from throttle bodyPull intake manifold out.R1503motr62A1INTAKE MANIFOLD1. GasketsLMR2004_008_04_03A.FM 04-03-5

Section 04 ENGINE (4-TEC)Subsection 03 (INTAKE SYSTEM)First, position intake manifold on front mountingbracket then push manifold toward engine to thusallow proceeding with rear mounting bracket.When installing the intake manifold, lift up the oildipstick tube a little bit to fit in the slot of the manifold.1R1503motr59B1. Oil dipstick tubeApply Loctite 243 (blue) (threadlocker) on the intakemanifold screws. Torque them to 10 N•m(89 lbf•in) following the tightening sequenceshown.453 1267R1503motr210AEnsure to properly route and resecure wiring harnesswith locking ties. WARNINGAlways check O-ring for damage such as deformationat reinstallation. Replace the O-ring if it isdamaged.04-03-6 LMR2004_008_04_03A.FM

Section 04 ENGINE (4-TEC)Subsection 04 (EXHAUST SYSTEM)EXHAUST SYSTEM 0PORT SIDE VIEW1517182116161620171213192022Hull14F13D04SLMR2004-009-04-04A.FM 04-04-1

Section 04 ENGINE (4-TEC)Subsection 04 (EXHAUST SYSTEM)STARBOARD VIEW1513618812161716207192022Hull14F13D05S04-04-2 LMR2004-009-04-04A.FM

Section 04 ENGINE (4-TEC)Subsection 04 (EXHAUST SYSTEM)EXHAUST PIPENOTE: This procedure to be performed for eachengine.Removal WARNINGCertain components in the engine compartmentmay be very hot. Direct contact may resultin skin burn. Let exhaust system cool downprior to removing parts.Disconnect the 3 cooling hoses from exhaust pipeno. 1.1F13D08A 121. Exhaust pipe clamp2. Exhaust pipeLoosen both sets of exhaust hose clamps no. 16and remove the exhaust hose no. 17 between themufflers no. 7 and no. 19.Detach the strap no. 12 from the muffler no. 7 usingthe spring installer/remover (P/N 529 035 559).23A00C3SAF13D07ATYPICAL — PORT ENGINE SHOWN1. Exhaust pipe2. Gear clamp3. Exhaust clampLoosen the exhaust hose clamps no. 6 to the hoseno. 18 between muffler no. 7 and the exhaustpipe no. 1.12F13D09ATYPICAL1. Muffler2. StrapLMR2004-009-04-04A.FM 04-04-3

Section 04 ENGINE (4-TEC)Subsection 04 (EXHAUST SYSTEM)Slowly unscrew exhaust clamp nut no. 5 and removeit.NOTE: Unscrewing the nut too fast generates heatthat will make it harder to unscrew.F18D0SATYPICAL1. Exhaust clamp2. Exhaust pipe2Move muffler no. 7 backward enough to allow theexhaust pipe to be pulled out.Apply sealant (P/N 413 710 200) on the welds of theexhaust tube, while the exhaust pipe is removedfrom the muffler no. 7.1InspectionInspect exhaust pipe condition paying attentionfor cracks or other damage. Check joints, couplingareas, heat shield and hoses. Replace any defectivepart.InstallationInstallation is essentially the reverse of the removalprocedures. However, pay particular attention tothe following:Insert the exhaust pipe end in the exhaust hose.Align the exhaust pipe flange with the engine manifold.To achieve a good fit, it could be necessary to pushthe exhaust pipe further down into the hose overthe step of the exhaust pipe. Take note of the dimensionit is over the step, then cut the hose bythis dimension, if necessary.Pre-align the exhaust pipe no. 1 by rotating (axially)and moving (longitudinally) the muffler no. 7 sothat the exhaust pipe flange makes perfect contactwith the engine manifold. A maximum gap of1 mm (3/64 in) is allowed.21F18D0TA 21. Sealant (P/N 413 710 200)2. Exhaust tube1F18D0UA1. Engine manifold2. Exhaust pipe flangeCAUTION: Exhaust pipe alignment with themanifold is critical to the bellows life. Any constrainton the flexible joint will result in the bellowsfailure. Gap between the exhaust pipeflange and the engine manifold should not exceed1 mm (3/64 in).04-04-4 LMR2004-009-04-04A.FM

Section 04 ENGINE (4-TEC)Subsection 04 (EXHAUST SYSTEM)Reinstall the exhaust clamp no. 5 to the exhaustpipe flange and tighten enough to maintain the exhaustpipe in the proper position.EXHAUST MANIFOLDRemovalDisconnect the cooling hoses from the exhaustpipe no. 1.Remove the exhaust clamp no. 5 and detach themuffler no. 7 from its support. Move the mufflerno. 7 rearwards to separate the exhaust pipe fromthe manifold if necessary. See above in EXHAUSTPIPE.Disconnect the cooling system supply hose no. 9underneath the front part of the exhaust manifold.F18D0XA 3 211. Exhaust pipe flange2. Exhaust clamp3. Engine manifoldTorque the exhaust clamp no. 5 to 11 N•m(97 lbf•in) while maintaining the exhaust pipe inthe proper position.Reinstall the muffler no. 7 strap no. 12 using thespring installer/remover (P/N 529 035 559). Caremust be taken not to induce strain in the flexiblejoint of the exhaust tube.Torque the clamps located in the upper part of themuffler no. 7 hose to 8 N•m (71 lbf•in). Care mustbe taken not to induce strain in the flexible joint ofthe exhaust tube.Reconnect the water lines to the exhaust pipe andtorque gear clamps to 8 N•m (71 lbf•in).CAUTION: Never run engine without supplyingwater to the exhaust cooling system whensport boat is out of water.After installation, ensure there is no water or exhaustgas leak when engine is running. Test runthe engine while supplying water to the flushingconnector.R1503motr151A 21. Exhaust manifold2. Cooling system supply hose locationUnscrew the exhaust manifold no. 10 beginningwith the bottom screws. This will help hold the manifoldin place while you remove the screws.Remove the manifold.InspectionInspect exhaust manifold condition paying attentionfor cracks or other damage. Check contactsurfaces and hose. Replace any defective part.Inspect plane surfaces for warpage. Small deformationcan be corrected by grinding surface witha fine sand paper. Install sand paper on a surfaceplate and rub part against oiled sand paper.Clean all metal components in a solvent.1LMR2004-009-04-04A.FM 04-04-5

Section 04 ENGINE (4-TEC)Subsection 04 (EXHAUST SYSTEM)InstallationInstallation is essentially the reverse of removalprocedures. However, pay particular attention tothe following:NOTE: There is no gasket between engine blockand exhaust manifold.Apply Loctite 518 (red) (gasket eliminator) on threadsof screws.To help hold the manifold in place while installingscrews, first insert the exhaust manifold into theexhaust pipe no. 1, then install the upper frontscrew. Continue with the remaining screws.Torque screws to 10 N•m (89 lbf•in) as per followingillustrated sequence. Repeat the procedure,torquing screws again to 10 N•m (89 lbf•in).7 5 1 3 9 11F13D0AATYPICAL1. Temperature sensor connector2. Outlet hoseDetach the strap no. 12 from the muffler no. 7 usingthe spring installer/remover (P/N 529 035 559).12A00C3SA12R1503motr152A8 6 4 2 10 12CAUTION: Never run engine without supplyingwater to the exhaust cooling system when watercraftis out of water.After installation, ensure there is no coolant or exhaustgas leak when the engine is running. Testrun the engine while supplying water to the flushingconnector.MUFFLERS (port engine)RemovalRemove the exhaust pipe no. 1. See above.Disconnect the temperature sensor connector.Loosen clamps no. 16 and disconnect the outlethose no. 17.F13D09A1. Muffler2. StrapCarefully pull out the muffler no. 7.Loosen clamps no. 20 and disconnect the exhausthose no. 21.04-04-6 LMR2004-009-04-04A.FM

Section 04 ENGINE (4-TEC)Subsection 04 (EXHAUST SYSTEM)Carefully remove the muffler no. 19.11F13D0BA1. Muffler2. StrapInspection2Inspect parts condition paying attention for cracksor other damage. Check hoses. Replace any defectivepart.F13D0CATYPICAL1. Disconnect inlet and outlet hoses from mufflerDetach the strap no. 13 from the muffler no. 19 usingthe spring installer/remover (P/N 529 035 559).InstallationInstallation is the reverse of the removal procedures.After installation, ensure there is no coolant or exhaustgas leak when the engine is running. Testrun the engine while supplying water to the flushingconnector.MUFFLERS (starboard engine)A00C3SA12RemovalLoosen both sets of exhaust hose clamps no. 16and no. 20 and disconnect the exhaust hosesno. 8 and no. 17 from the muffler no. 19.F13D0DA1. Muffler2. StrapCarefully pull out the muffler no. 19.LMR2004-009-04-04A.FM 04-04-7

Section 04 ENGINE (4-TEC)Subsection 04 (EXHAUST SYSTEM)InspectionInspect parts condition paying attention for cracksor other damage. Check hoses. Replace any defectivepart.InstallationInstallation is the reverse of the removal procedures.After installation, ensure there is no coolant or exhaustgas leak when the engine is running. Testrun the engine while supplying water to the flushingconnector.EXHAUST OUTLET(port and starboard)RemovalLoosen the two exhaust hose clamps no. 20 fromthe exhaust outlet no. 14 and disconnect the exhausthose.From inside of hull, unscrew nut no. 22 with theexhaust outlet tool (P/N 295 000 132).InspectionInspect parts condition paying attention for cracks orother damage. Check hose. Replace any defectivepart.InstallationInstallation is essentially the reverse of the removalprocedures. However, pay particular attention tothe following:Apply Loctite silicone sealant (P/N 293 800 086)on the stabilizing washer to seal the bilge.Ensure to tighten exhaust outlet hose clamps no. 20to 8 N•m (71 lbf•in).Test the bilge for water leaks.F01B2AAF09D0WA 1 2TYPICAL1. Exhaust outlet nut2. Tool04-04-8 LMR2004-009-04-04A.FM

Subsection 05Section 04 ENGINE (4-TEC)(REMOVAL AND INSTALLATION)REMOVAL AND INSTALLATION 0GENERALNOTE: This procedure to be performed for eachengine.Engine removal is necessary to repair BOTTOMEND.ENGINE REMOVALUse the VCK (Vehicle Communication Kit) (P/N 529035 844) and release the fuel pressure in the fuelsystem. Refer to ENGINE MANAGEMENT section.In order to remove engine from sport boat proceedas follows.First, disconnect battery cables from battery. WARNINGAlways disconnect battery cables exactly inthe specified order, BLACK negative cablefirst then the RED positive battery cable last.Electrical ConnectionsIt is recommended to disconnect electrical connectionsprior to disconnecting fuel lines.Disconnect magneto wiring harness.Disconnect the throttle position sensor (TPS), manifoldair pressure sensor (MAPS) and manifold air temperaturesensor (MATS) (refer to INTAKE section).Refer to ENGINE MANAGEMENT for location ofsensors and connectors.Drive SystemTo withdraw drive shaft, refer to PROPULSION section.Cooling SystemTo remove cooling system hoses, refer to COOLINGSYSTEM section.Exhaust PipeTo remove exhaust pipe, refer to EXHAUST SYSTEMin ENGINE section.Air Intake SilencerTo remove air intake silencer, refer to INTAKE.Engine SupportNOTE: Be careful when removing engine support(s)or rubber mount adapters, shims couldhave been installed underneath. Shims control engine/jetpump alignment. Always note position ofshims for reinstallation, to avoid altering enginealignment.Remove engine support mount screws.Jet Pump RemovalTo withdraw jet pump, refer to PROPULSION section.CAUTION: Whenever removing engine fromsport boat, engine/jet pump alignment must beperformed at reinstallation.F04D1SA1TYPICAL — FRONT SUPPORT1. Remove screwLMR2004_010_04_05A.FM 04-05-1

Section 04 ENGINE (4-TEC)Subsection 05 (REMOVAL AND INSTALLATION)Removal of Remaining ComponentsDisconnect RED positive cable from starter post.1F18D14A1TYPICAL — REAR SUPPORT1. Remove screwsLifting EngineUsing a chain block, a hoist or other suitable equipment,slightly lift engine to ease the remaining componentremoval.CAUTION: Take care not to damage cables.1F04H72ATYPICAL1. Disconnect RED positive cableCarry on the lifting engine to remove it through thebody opening.CAUTION: Be careful not to scratch body or tohit any component.CLEANINGRemove any spillage in bilge. Clean with a bilgecleaner.Clean external parts of engine.INSTALLATIONInstallation of engine in sport boat is essentiallythe reverse of removal procedures. However payparticular attention to the following.F04D1TA1TYPICAL1. Transport brackets04-05-2 LMR2004_010_04_05A.FM

Subsection 05Section 04 ENGINE (4-TEC)(REMOVAL AND INSTALLATION)Engine SupportLoctite 2431Loctite24311Loctite243F00B0FA 1 2TYPICAL1. Plate2. SupportAlignment shaft (P/N 295 000 141).F18D10A1. Torque screws to 25 N•m (18 lbf•ft)Positive Starter CableTorque nut of positive starter cable to 7 N•m(62 lbf•in). Apply dielectric grease on nut.Engine/Jet Pump AlignmentAlignment is necessary to eliminate possible vibrationand/or damage to components. Checkalignment of engine using the following alignmenttools.Support plate kit (P/N 529 035 506).NOTE: Use plate (P/N 529 035 507) for the 155.6 mm(6-1/8 in) jet pump.F00B0GA 11. Alignment shaftEngine alignment adapter (P/N 529 035 719).F18D16A1. Engine alignment adapter1LMR2004_010_04_05A.FM 04-05-3

Section 04 ENGINE (4-TEC)Subsection 05 (REMOVAL AND INSTALLATION)To verify alignment proceed as follows:– Install the appropriate plate with the support tohull with four nuts.F18D17A 12F04J4GATYPICAL– Install adaptor (P/N 529 035 719) on drive shaft.TYPICAL1. Engine alignment adapter2. Alignment shaftIf the alignment is incorrect loosen engine supportscrews to enable to align engine alignment adaptorwith shaft end.NOTE: Use shim(s) (P/N 270 000 024 or P/N 270000 025) as necessary between engine supportsand rubber mounts to correct alignment.F18D18A1TYPICAL1. Engine alignment adaptor– Carefully slide shaft through support.– Insert shaft end into engine alignment adaptor.NOTE: Ensure the protective hose and carbonring (or seal carrier) is removed to check enginealignment. If the alignment is correct, the shaft willslide easily without any deflection in engine alignmentadaptor.F18D15ATYPICAL1. ShimCAUTION: Whenever shims are used to correctalignment, never install more than 5 mm (0.196 in)shim thickness.104-05-4 LMR2004_010_04_05A.FM

Subsection 05Section 04 ENGINE (4-TEC)(REMOVAL AND INSTALLATION)Engine Support ScrewsApply Loctite 243 (blue) (threadlocker) (P/N 293 800060) on screw threads.Torque engine support screws to 25 N•m (18 lbf•ft)when procedure is completed.Loctite 2431Loctite2431F18D14A1TYPICAL1. Torque to 25 N•m (18 lbf•ft)F18D10A11. Torque to 25 N•m (18 lbf•ft)F04D1SALoctite2431. Torque to 25 N•m (18 lbf•ft)1Rubber Mount, Shim and ScrewCheck tightness and condition of rubber mounts. Ifthey have been removed, apply Loctite 243 (blue) onscrew threads. Torque screws to 25 N•m (18 lbf•ft).CAUTION: Strict adherence to this torque is importantto avoid damaging threads of aluminuminsert in bilge.Properly align exhaust pipe. Refer to EXHAUSTSYSTEM in ENGINE section.Final InspectionCheck throttle cable conditions and lubricate cableswith BOMBARDIER LUBE lubricant.After installation, properly adjust throttle cables asspecified in ENGINE MANAGEMENT.Check hose condition and pressure test fuel system,refer to FUEL SYSTEM section. WARNINGWhenever doing any type of repair on sportboat or if any components of the fuel systemare disconnected, a pressure test must bedone before starting engine.Verify all electrical connections.Run each engine to ensure there is no leakage.CAUTION: If sport boat is out of water, each enginemust be cooled using the flush kit.LMR2004_010_04_05A.FM 04-05-5

Section 04 ENGINE (4-TEC)Subsection 06 (PTO HOUSING/MAGNETO)PTO HOUSING/MAGNETO10 N•m(89 lbf•in)224 N•m(18 lbf•ft)Loctite2433 N•m (27 lbf•in)Left handed threadsEngine oil10 N•m (89 lbf•in)104Loctite243Engine oilLoctite 243111512 N•m(106 lbf•in)10 N•m(89 lbf•in)10 N•m(89 lbf•in)318 N•m(159 lbf•in)Engine oilEngineoilMulti-purposegrease30 N•m(22 lbf•ft)9 24 N•m(18 lbf•ft)1517 16LoctiteLoctite 5910 24319Loctite24318Loctite243142010 N•m(89 lbf•in)Engine oil7 621810 N•m(89 lbf•in)Engineoil250 N•m(184 lbf•ft)1312Loctite anti-seizeR1503motr57SLMR2004_011_04_06A.FM 04-06-1

Section 04 ENGINE (4-TEC)Subsection 06 (PTO HOUSING/MAGNETO)GENERALNOTE: This procedure to be performed for eachengine.Always perform the electric tests before removingor installing any components.Clean threads before using Loctite when installingthe screws.PTO HOUSINGRemovalNOTE: When drive shaft will be removed, someoil will flow out. To prevent it, start engine, run at4000 RPM for 10 seconds and stop engine at thisRPM. This will move oil out of PTO housing intooil tank.CAUTION: Never run engine(s) without supplyingwater to the exhaust cooling system whensport boat is out of water.If engine(s) cannot be started, up to 1 L (34 oz)could flow out at PTO housing removal. To preventthis, follow instructions REMOVING OIL IN PTOHOUSING WHEN ENGINE CANNOT BE START-ED below. Otherwise, skip to instructions PTOHOUSING REMOVAL below.Removing Oil in PTO Housing when Enginecannot be StartedRemove chain tensioner plug screw and tensioner.Refer to ENGINE BLOCK subsection.R1503motr39A 11. Plug screw2. Gasket ring3. Chain tensioner3Remove valve cover. Refer to CYLINDER HEADAND VALVES subsection.2A tube is to be inserted to siphon oil out of PTOhousing. To ensure tube will be inserted far inenough, measure 381 mm (15-3/8 in) from tubeend (the end that will be inserted in engine) andtrace a mark or put tape on the tube at this location.Insert the tube along timing chain as shown untilyou reach the mark (or tape). Then, siphon the oilout using the oil VAC (P/N 529 035 880).1F18D2KAAPTO HOUSING AND MAGNETO REMOVED FOR EXPLANATION1. Siphon tubeA. 381 mm (15-3/8 in) from tube endPTO Housing RemovalDrain engine oil. Refer to LUBRICATION in EN-GINE section.Place rags under PTO housing to prevent spillage.Up to 250 mL (8 oz) of oil could flow out when removingPTO housing. If spillage occurs, clean immediatelywith the pulley flange cleaner (P/N 413711 809) to prevent oil stains.Disconnect CPS and magneto generator from wiringharness. WARNINGAlways disconnect battery or starter cablesexactly in the specified order, BLACK negativecable first. Disconnect electrical connectionsprior to disconnecting fuel lines.04-06-2 LMR2004_011_04_06A.FM

Section 04 ENGINE (4-TEC)Subsection 06 (PTO HOUSING/MAGNETO)Remove:– jet pump(refer to JET PUMP in PROPULSION SYSTEM)– drive shaft (refer to DRIVE SYSTEM in PRO-PULSION SYSTEM)– slightly lift rear part of engine and safely block inthis position. Remove rear LH side engine supportno. 1.NOTE: Carefully separate the PTO housing fromthe engine using two flat screwdrivers pryingequally at the same time. Proceed slowly so thatstarter gear disc springs no. 6 and washer no. 7do not fall down.– PTO housing no. 5CAUTION: Ensure to use prying lugs to separatePTO housing to prevent damaging contactsurface.3112R1503motr50A1. Engine supportRemove:– thru-hull fitting bootF18J0BA1. Thru-hull fitting boot2. Remove this collar– coolant pump housing no. 2(refer to COOLING SYSTEM)– screws nos. 3 and 412R1503motr58A1. Disc springs2. Washer3. Starter drive gear– gasket no. 9.InspectionCheck PTO housing for cracks or other damages.Replace if necessary.InstallationNOTE: Clean all metal component in a non-ferrousmetal cleaner. WARNINGWear safety glasses and work in a well ventilatedarea when working with strong chemicalproducts. Also wear suitable non-absorbentgloves to protect your hands.For installation, reverse the removal procedure.However, pay attention to the following.NOTE: Turn the oil/coolant pump shaft in the rightposition to fit into the balance shaft.LMR2004_011_04_06A.FM 04-06-3

Section 04 ENGINE (4-TEC)Subsection 06 (PTO HOUSING/MAGNETO)Position the disc springs no. 6 and washer no. 7as per the following illustration.21221 2 3 4R1503motr46A1. Washer2. Disc spring3. Flange washer4. Starter drive ass’yCAUTION: Ensure the starter drive gear shaft iswell engaged in its bore.Gently install PTO housing.CAUTION: While installing housing, pay particularattention that gasket does not get pinchedor slide out of its contact surface in the areashown in the following illustration. Never forceto install cover. If there is a strong resistance,remove housing and check oil/coolant pumpalignment and starter gear alignment.R1503motr15A1. Screws M6 x 352. Screws M6 x 85Tightening sequence for screws on PTO housingis as per following illustration.1511421 13 12111102116179188192021 2 3 4 567R1503motr15BF18D2LA1. Pay attention that gasket remains properly positioned on thissurfaceRefer to the following illustration for proper installationof screws.Reinstall LH engine support. Apply Loctite 243 (blue)on screw threads then torque to 24 N•m (18 lbf•ft).Remove block under engine.Properly reinstall chain tensioner. Refer to EN-GINE BLOCK subsection.Properly reinstall valve cover. Refer to CYLINDER-HEAD AND VALVES subsection.Refill engine with oil and cooling system with coolant.Refer to ENGINE and COOLING SYSTEM sections.Check engine alignment. Refer to REMOV-AL AND INSTALLATION in ENGINE section.04-06-4 LMR2004_011_04_06A.FM

Section 04 ENGINE (4-TEC)Subsection 06 (PTO HOUSING/MAGNETO)PTO SEALInspectionCheck the PTO seal no. 10 on the PTO housing. Ifbrittle, hard or damaged, or if you see a sign of oilleakage, replace it.RemovalNOTE: When drive shaft will be removed, someoil will flow out. To prevent it, start engine, run at4000 RPM for 10 seconds and stop engine at thisRPM. This will move oil out of PTO housing intooil tank.CAUTION: Never run engine without supplyingwater to the exhaust cooling system whensport boat is out of water.Place rags under PTO housing to prevent spillage.If spillage occurs, clean immediately with the PulleyFlange Cleaner (P/N 413 711 809) to preventoil stains.Remove:– Oetiker clamp no. 11 located close to the PTOhousing– jet pump(refer to JET PUMP in PROPULSION SYSTEM)– drive shaft (refer to DRIVE SYSTEM in PROPUL-SION SYSTEM)– PTO seal no. 10.2COUPLINGRemovalLock crankshaft with locking tool (P/N 529 035821). Refer to CRANKSHAFT LOCKING in ENGINEBLOCK subsection.Remove:– jet pump– drive shaft– PTO seal as described above– coupling no. 12 using impeller remover/installer(P/N 529 035 820).CAUTION: Apply some oil on the tool to protectthe seal located in the PTO coupling.R1503motr48AInspectionCheck if seal no. 13 is brittle, cracked or hard. Checkcoupling for worn splines.If damaged, replace faulty part.R1503motr47A11. PTO seal2. Oetiker clampsInstallationReinstall removed parts in the reverse order.R1503motr49ALMR2004_011_04_06A.FM 04-06-5

Section 04 ENGINE (4-TEC)Subsection 06 (PTO HOUSING/MAGNETO)InstallationFor installation, reverse the removal procedure.However, pay attention to the following.Torque PTO coupling to 250 N•m (184 lbf•ft). ApplyLoctite anti-seize on threads.STATOR12RemovalRemove:– PTO housing (refer to PTO HOUSING REMOV-AL elsewhere in this section)– holding plate no. 14 with CPS no. 15R1503motr26AR1503motr21A 121. CPS screws2. Holding plate3. CPS– screws no. 16– stator no. 17.31. Stator screws2. StatorInspectionCheck stator and CPS condition. If damaged replacethe faulty part.For electrical inspection, refer to CHARGING SYS-TEM for the stator and to ENGINE MANAGE-MENT for the CPS.InstallationFor installation, reverse the removal procedure.However, pay attention to the following.NOTE: There is only one position for the stator(notch in the magneto housing cover).R1503motr51A11. Notch for stator04-06-6 LMR2004_011_04_06A.FM

Section 04 ENGINE (4-TEC)Subsection 06 (PTO HOUSING/MAGNETO)Place the rubber grommets on both cables in theproper notches at the PTO housing.21InspectionCheck rotor, bent teeth and encoder wheel condition.If damaged, replace faulty part.InstallationFor installation, reverse the removal procedure.However, pay attention to the following.Encoder wheel position has to be located with thelocation pin on the crankshaft gear.IMPORTANT: If rotor has balancing holes, neverinstall it so that they are inside the large gap betweenencoder wheel teeth. This would create anon-starting condition of the engine.R1503motr52A1. Grommet on CPS cable2. Grommet on stator cableApply Loctite 243 on threads.Torque stator andCPS screws to 10 N•m (89 lbf•in).4ROTOR AND ENCODER WHEELRemovalLock crankshaft with locking tool (P/N 529 035821). Refer to CRANKSHAFT LOCKING in ENGINEBLOCK subsection.Remove:– PTO housing– hexagonal screws no. 18 retaining rotor.Withdraw rotor no. 19 with encoder wheel no. 20.2131F18D0AA 2 1 3WRONG INSTALLATION1. Rotor2. Balancing holes3. Encoder wheel4. Large gapApply Loctite 243 on threads.Torque rotor screwsto 24 N•m (18 lbf•ft).RING GEARRemovalLock crankshaft with locking tool (P/N 529 035821). Refer to CRANKSHAFT LOCKING in ENGINEBLOCK subsection.Remove:– PTO housing cover– hexagonal screws no. 18.R1503motr53A1. Hexagonal screws2. Rotor3. Encoder wheelLMR2004_011_04_06A.FM 04-06-7

Section 04 ENGINE (4-TEC)Subsection 06 (PTO HOUSING/MAGNETO)Withdraw rotor no. 19, encoder wheel no. 20 andstarter ring no. 21.234STARTER DRIVE ASS’YRemovalRemove:– PTO housing and ring gear as described above– starter drive ass’y no. 8.1R1503motr54A1. Hexagonal screws2. Rotor3. Encoder wheel4. Ring gearInspectionCheck ring gear condition, especially teeth condition.If damaged, replace faulty part.InstallationFor installation, reverse the removal procedure.However, pay attention to the following.Ring gear and encoder wheel position has to belocated with the location pin on the crankshaftgear.R1503motr55A1. Starter drive ass’yCAUTION: Be careful not to lose the distancewasher, disc springs no. 6 and washer no. 7 locatedon the starter drive shaft.311212R1503motr58AR1503motr54B1. Location pin2. Location pin holesApply Loctite 243 on threads.Torque rotor screwsto 24 N•m (18 lbf•ft).1. Disc springs2. Washer3. Starter drive gearInspectionCheck condition of the teeth, shaft, etc. and if thesprag clutch operates well. If damaged, replacefaulty part.04-06-8 LMR2004_011_04_06A.FM

Section 04 ENGINE (4-TEC)Subsection 06 (PTO HOUSING/MAGNETO)InstallationFor installation, reverse the removal procedure.However, pay attention to the following.Apply some Isoflex Topas NB52 grease (P/N 293550 021) on the starter drive bearing located in theengine block and on the starter drive support in thePTO housing cover.1R1503motr56A1. Starter drive bearing1R1503motr45A1. Starter drive supportCAUTION: Be sure to remember the distancewasher, disc springs and washer on the starterdrive shaft when assembling.LMR2004_011_04_06A.FM 04-06-9

Section 04 ENGINE (4-TEC)Subsection 07 (LUBRICATION SYSTEM)LUBRICATION SYSTEM10 N•m(89 lbf•in)110 N•m(89 lbf•in)Loctite24324310 N•m(89 lbf•in)Engine oilMulti-purposegrease28 N•m(21 lbf•ft)193 N•m (27 lbf•in) 20Left handed threads 25 26Engine oil10 N•m (89 lbf•in)Loctite 243 51817Engine oil1615Loctite 24312 N•m(106 lbf•in)392318 N•m(159 lbf•in)3233 3124Engineoil622Loctite243Loctite24324 N•m(18 lbf•ft)Loctite 59102110 N•m(89 lbf•in)Loctite24310 N•m(89 lbf•in)R1503motr112SLMR2004_012_04_07A.FM 04-07-1

Section 04 ENGINE (4-TEC)Subsection 07 (LUBRICATION SYSTEM)18 N•m(159 lbf•in)Loctite 24335Oil10 N•m(89 lbf•in)34Oil18 N•m(159 lbf•in)710 N•m(89 lbf•in)Loctite 243Loctite 243Loctite 243810 N•m(89 lbf•in)Loctite24310 N•m(89 lbf•in)Loctite 243Loctite 243Horizontalto exhaust side14Oil1327 937382829Oil36Loctite 243 4030Oil10 N•m1018 N•m(89 lbf•in)(159 lbf•in) Loctite 24342 1210 N•m 10 N•m Loctite 243(89 lbf•in) (89 lbf•in) 11OilOil5-25 N•m(44-221 lbf•in)10 N•m(89 lbf•in)R1503motr113S04-07-2 LMR2004_012_04_07A.FM

Section 04 ENGINE (4-TEC)Subsection 07 (LUBRICATION SYSTEM)GENERALNOTE: This procedure to be performed for each engine.Prior to changing the oil, ensure vehicle is on alevel surface.Oil and oil filter must be replaced at the same time.Oil change and oil filter replacement should bedone with a warm engine. WARNINGThe engine oil can be very hot. Wait until engineoil is warm.Dispose of oil and filter(s) as per your local environmentalregulations.OIL LEVEL VERIFICATIONCAUTION: Check levels frequently and refill ifnecessary. Do not overfill — it would make theengines smoke and reduce power. Operatingthe engines with an improper oil level may severelydamage engines. Wipe off any spillage.12. If out of water, raise trailer tongue and block inposition when bumper rail is level. Install a gardenhose to the flushing connector. Refer toFLUSHING in MAINTENANCE and follow theprocedures.CAUTION: Failure to flush exhaust cooling systems,when engines are out of water, may severelydamage engines and/or exhaust systems.3. Warm-up engine then let idle for 30 secondsbefore stopping.4. Stop engine.5. Wait at least 30 seconds then pull dipstick outand wipe clean. WARNINGEngine oil may be hot. Certain components inthe engine compartment may be very hot. Directcontact may result in skin burn.CAUTION: Never run engine(s) longer than 5minutes. Drive line seals have no cooling whensport boat is out of water.6. Reinstall dipstick, push in completely.7. Remove each dipstick and read oil level. Oil levelreading should be between marks.3F04G0NA1. DipstickCheck the oil level as follows:1. Sport boat must be level. Check oil level eitherwith sport boat in water or out of water. Engineshould be warm.CAUTION: Never run engine(s) without supplyingwater to the exhaust cooling systems whensport boat is out of water.F18D05A21. Full2. Add3. Operating range8. Otherwise, add oil up to have the level betweenmarks as required.NOTE: This procedure to be performed for each engine.To add oil, unscrew oil cap. Place a funnel into theopening and add the recommended oil to the properlevel. Do not overfill.ENGINE PRESSURE TESTNOTE: The engine pressure test should be donewith a warm engine and the recommended oil.Remove plug below oil filter housing.1LMR2004_012_04_07A.FM 04-07-3

Section 04 ENGINE (4-TEC)Subsection 07 (LUBRICATION SYSTEM)Use oil pressure gauge (P/N 529 035 709) andhose adaptor (P/N 529 035 652) and install whereshown.Start engine and read pressure at different RPMas per following table.F18G03A 1 21. Oil filter housing2. Pressure test plugNOTE: Oil pressure switch works between 180 kPa(26 PSI) and 220 kPa (32 PSI).The engine oil pressure should be within the followingvalues.CAUTION: Failure to flush exhaust cooling systems,when engines are out of water, may severelydamage engines and/or exhaust systems. WARNINGEngine oil may be hot. Certain components inthe engine compartment may be very hot. Directcontact may result in skin burn.CAUTION: Never run engines longer than 5minutes. Drive line seals have no cooling whensport boat is out of water.Run engine for 10 seconds at 4000 RPM and shutit off at this RPM. This will move oil from PTOhousing to oil tank to allow maximum oil draining.Remove oil filler cap and dipstick.Using the oil VAC (P/N529 035 880), siphon oilthrough dipstick hole.CAUTION: Never crank or start an engine whensiphon tube is in dipstick hole. Never start anengine when there is no oil in it.NOTE: So that siphon tube is located at the properheight to siphon oil, it is suggested to put someelectrical tape on siphon tube at 475 mm (18.7 in)from its end. Then, insert siphon tube until youreach the tape.OIL PRESSURE TESTENGINE RPM PRESSURE kPa (PSI)Idle (cold) 300 - 400 (44 - 58)Idle (at 80°C (176°F)) min. 160 (23)4000 - 7500 300 - 400 (44 - 58)2If the engine oil pressure is out of specifications,check the points described in TROUBLESHOOT-ING section.Reinstall plug.Oil ChangeEngine in VehicleNOTE: If water is found in oil (oil will appear milky),refer to submerged engine in MAINTENANCE sectionand follow the procedure to flush it.Bring engine to its normal operating temperature.CAUTION: Never run engines without supplyingwater to the exhaust cooling systems whensport boat is out of water.1F13G01ATYPICAL1. Oil VAC2. Siphon tube to dipstick hole04-07-4 LMR2004_012_04_07A.FM

Section 04 ENGINE (4-TEC)Subsection 07 (LUBRICATION SYSTEM)From engine compartment, have a second personhold throttle bell crank in fully opened position.F13G04A1F13G02A1. Fully-opened positionCrank engine for 10 seconds. Siphon oil again. Repeatthe crank-siphon cycle 2-3 times.Once oil change is completed, ensure throttle cableis positioned correctly in the throttle bell crank.11. CorrectEngine RemovedEach engine has two separate drain plugs. One islocated in the lower crankcase half and the otherone in the PTO housing.F13G03A1. Incorrect1R1503motr211A 11. Drain plugsPlace a drain pan under the engine drain plug area.Clean the drain plug area.Unscrew drain plugs no. 39 and no. 40 then removedipstick.CAUTION: Pay attention not to lose gasketrings on drain plug.Wait a while to allow oil to flow out of oil filter.Change gasket ring on drain plug if damaged.InspectionOil condition gives information about the enginecondition. See TROUBLESHOOTING section.InstallationReinstall removed parts and fill in the new engine oil.LMR2004_012_04_07A.FM 04-07-5

Section 04 ENGINE (4-TEC)Subsection 07 (LUBRICATION SYSTEM)Oil Type and System CapacityRefer to TECHNICAL DATA. For refilling procedure,refer to OIL LEVEL VERIFICATION above.OIL FILTERRemovalRemove:– engine oil (refer to OIL CHANGE)– oil filter screw no. 1– oil filter cover no. 2– oil filter no. 3.3 21R1503motr115A 2 11. Inlet bore from the oil pump to the oil filter2. Outlet bore to the engine oil providing systemInstallationThe installation is the opposite of the removal procedure.Pay attention to the following details.Install a new oil filter.Install O-ring on oil filter cover.R1503motr114A1. Oil filter screw2. Oil filter cover3. Oil filterPlace rags in fillet area to prevent spillage. If spillageoccurs, clean immediately with the pulleyflange cleaner (P/N 413 711 809) to prevent stains. WARNINGWear safety glasses and work in a well ventilatedarea when working with strong chemicalproducts. Also wear suitable non-absorbentgloves to protect your hands.InspectionCheck oil filter cover O-ring no. 4 and oil filter screwO-ring, change if necessary.Check and clean the oil filter inlet and outlet areafor dirt and other contaminations.R1503motr116ATorque oil filter screw to 10 N•m (89 lbf•in).OIL STRAINERSThe oil strainers do not need to be cleaned at everyoil change. Clean them during other inspections,especially when the engine is disassembled.04-07-6 LMR2004_012_04_07A.FM

Section 04 ENGINE (4-TEC)Subsection 07 (LUBRICATION SYSTEM)PTO - Oil StrainerRemovalRemove:– engine oil (refer to OIL CHANGE)– PTO cover no. 5(refer to PTO COVER/MAGNETO section)– oil strainer no. 6.1R1503motr118A11. Oil inlet to the oil pumpR1503motr117A1. Oil strainerCleaning and InspectionClean oil strainer with a part cleaner then use anair gun to dry it. WARNINGAlways wear eye protection. Chemicals cancause a rash to break out in and/or an injuryto your eyes.InstallationFor installation, reverse the removal procedure.Refill engine at the proper level with the recommendedoil. Refer to TECHNICAL DATA for capacityand OIL LEVEL VERIFICATION above for procedure.Suction Pump - Oil StrainerRemoval– Remove blow-by ventilation hose no. 7.1Check and clean the oil outlet area for dirt and othercontaminants.R1503motr133A1. Blow-by ventilation hose– Disconnect wiring harness from blow-by valveno. 8 and blow-by pressure switch no. 9.– Detach air intake hose from the throttle body.LMR2004_012_04_07A.FM 04-07-7

Section 04 ENGINE (4-TEC)Subsection 07 (LUBRICATION SYSTEM)– Disconnect battery cables then remove battery.Refer to BATTERY in CHARGING SYSTEM sectionfor proper procedures.– Remove retaining screws no. 10 and no. 11.– Place rags under cover to prevent spillage. Ifspillage occurs, clean immediately with the pulleyflange cleaner (P/N 413 711 809) to preventstains. WARNINGWear safety glasses and work in a well ventilatedarea when working with strong chemicalproducts. Also wear suitable non-absorbentgloves to protect your hands.Inspect rubber rings no. 13 and no. 14.12– Remove suction pump cover with oil separator.– Remove oil strainer no. 12.R1503motr121A1. O-ring2. Rubber ring gasketIf rubber rings are brittle, cracked or hard, replacethem.Clean both contact surfaces of oil strainer cover.Check and clean the oil inlet and outlet area for dirtand other contaminations.R1503motr120A11. Oil strainerCleaning and InspectionClean oil strainer with a part cleaner then use anair gun to dry it. WARNINGAlways wear eye protection. Chemicals cancause a rash to break out in and/or an injuryto your eyes.R1503motr122A11. Oil inlet to the oil pump04-07-8 LMR2004_012_04_07A.FM

Section 04 ENGINE (4-TEC)Subsection 07 (LUBRICATION SYSTEM)InstallationFor installation, reverse the removal procedure.Position screw length as shown.1R1503motr123A1. Oil pressure regulatorNOTE: The oil pressure regulator system openswhen the oil pressure exceeds 400 kPa (58 PSI).R1503motr119A 121. Screws M6 x 252. Screws M6 x 85Torque suction pump cover screws to 10 N•m(89 lbf•in) as per sequence illustrated below. ApplyLoctite 243 on threads.61RemovalRemove:– engine oil (refer to OIL CHANGE)– oil pressure regulator plug no. 15, compressionspring no. 16, valve piston no. 17 and valve pistonguide no. 18. WARNINGOil pressure regulator plug on oil pump housingis spring loaded.523R1503motr144A4ENGINE OIL PRESSUREREGULATORThe oil pressure regulator is located on the bottomof the PTO housing.R1503motr124A 4 3 21. Valve piston guide2. Valve piston3. Compression spring4. Oil pressure regulator plug1LMR2004_012_04_07A.FM 04-07-9

Section 04 ENGINE (4-TEC)Subsection 07 (LUBRICATION SYSTEM)InspectionInspect valve piston and valve piston guide forscoring or other damages.Check compression spring for free length.2COMPRESSION SPRING FREE LENGTHNEW NOMINALSERVICE LIMIT60 mm (2.362 in)50.3 mm (1.980 in)Replace parts if important wear or damage arepresent.Clean bore and threads in the PTO housing frommetal shavings and other contaminations.InstallationFor installation, reverse the removal procedure.Pay attention to the following details.Be careful that the O-ring on plug screw is in place.Torque plug screw to 12 N•m (106 lbf•in) maximum.Apply Loctite 243 on threads.R1503motr125A1. Screws2. Oil pump cover– outer oil pump rotor no. 23.11OIL PRESSURE PUMPThe oil pressure pump is located in the PTO housingand is driven by the balance shaft.RemovalRemove:– engine oil (refer to OIL CHANGE)– PTO housing(refer to PTO HOUSING/MAGNETO section)– Coolant pump housing no. 19 and impellerno. 20. (refer to COOLING SYSTEM section)– screws no. 21– oil pump cover no. 22R1503motr126A1. Outer oil pump rotor– Extract the coolant/oil pump shaft no. 24 fromoutside PTO housing with a pusher.– Remove rotary seal no. 25 with a screwdriver.04-07-10 LMR2004_012_04_07A.FM

Section 04 ENGINE (4-TEC)Subsection 07 (LUBRICATION SYSTEM)R1503motr127ACAUTION: Be careful not to damage the surfaceof the rotary seal bore in PTO housing cover.– Oil seal no. 26.1R1503motr129A1. Pittings on the teethUsing a feeler gauge, measure the clearance betweeninner and outer rotors.AB1CR1503motr130A 21R1503motr128A1. Oil sealInspectionInspect oil pump shaft assembly, housing and coverfor marks or other damages.Check inner rotor for corrosion pin-holes or otherdamages. If so, replace oil pump shaft assembly.Ensure to also check oil pump housing and coverand replace if damaged.1. Outer rotor2. Inner rotorOUTER AND INNER ROTOR CLEARANCEmm (in)SERVICE LIMITAB0.25 mm (.009 in)CIf clearance between inner and outer rotors exceedsthe tolerance, replace coolant/oil pumpshaft assembly. Ensure to also check oil pumphousing and cover and replace if damaged.If clearance between outer rotor and its bore in oilpump exceeds the tolerance, replace the completeoil pump and the PTO housing.LMR2004_012_04_07A.FM 04-07-11

Section 04 ENGINE (4-TEC)Subsection 07 (LUBRICATION SYSTEM)Using a vernier depth gauge, measure side wearas shown.InstallationFor installation, reverse the removal procedure.Pay attention to the following details.NOTE: Never use oil in the press fit area of therotary seal.Push coolant/oil pump shaft seal in place by usingthumb.1R1503motr131A 211. PTO housing surface2. Vernier depth gaugeR1503motr128AR1503motr132A 211. Oil pump outer rotor surface2. Vernier depth gageDifference between pump housing and outer rotorshould not exceed 0.1 mm (.004 in). If so, replacereplace the complete oil pump assembly.NOTE: When the axial clearance of the oil pumpshaft assembly increases, the oil pressure decreases.Check the inside of oil pump housing and its coverfor scoring or other damages and replace if damaged.1. Oil sealInstall the new rotary seal by using the rotary sealpusher (P/N 529 035 823).CAUTION: Never use a hammer for the rotaryseal or coolant/oil pump shaft installation. Onlyuse a press to avoid damaging the ceramiccomponent.R1503motr141A 211. Rotary seal2. Rotary seal pusher04-07-12 LMR2004_012_04_07A.FM

Section 04 ENGINE (4-TEC)Subsection 07 (LUBRICATION SYSTEM)Install the coolant/oil pump shaft using the rotaryseal pusher (P/N 529 035 823) on the oppositeside to support the rotary seal. Use the oil sealguide (P/N 529 035 822) with a press.OIL SUCTION PUMPThe oil suction pump is located on the front sideof the engine at the bottom of the oil separator.Removal– Remove blow-by ventilation hose no. 7.1R1503motr142A 211. Oil seal guide2. Coolant/oil pump shaft1R1503motr133AR1503motr143A1. Coolant/oil pump shaft with oil seal guide2. Rotary seal pusherTighten oil pump cover screws and torque to 10 N•m(89 lbf•in). Apply Loctite 243 on threads.Final TestAfter engine is completely reassembled, start engineand make sure oil pressure is within specifications.21. Blow-by ventilation hose– Disconnect wiring harness from blow-by pressureswitch no. 9 and blow-by valve no. 8.– Detach air silencer from throttle body.– Disconnect battery cables and vent tube thenremove battery. Refer to BATTERY in CHARG-ING SYSTEM section for proper procedures.– Remove retaining screws no. 42.– Place rags under cover to prevent spillage. Ifspillage occurs, clean immediately with the pulleyflange cleaner (P/N 413 711 809) to preventstains. WARNINGWear safety glasses and work in a well ventilatedarea when working with strong chemicalproducts. Also wear suitable non-absorbentgloves to protect your hands.– Remove oil suction pump housing with oil separator.LMR2004_012_04_07A.FM 04-07-13

Section 04 ENGINE (4-TEC)Subsection 07 (LUBRICATION SYSTEM)– Remove oil pump screws no. 27 and coverno. 28.1R1503motr137AR1503motr135A1. Oil pump cover– Remove oil pump shaft ass’y no. 29.– Remove outer rotor no. 30.11. Pittings on the teethUsing a feeler gauge, measure the clearance betweeninner and outer rotors.BACR1503motr138A 2 11. Outer rotor2. Inner rotorR1503motr136A 1 21. Oil pump shaft ass’y2. Outer rotorInspectionInspect oil pump shaft assembly, housing and coverfor marks or other damages.Check inner rotor for corrosion, pin-holes or otherdamages. If so, replace oil pump shaft assembly.Ensure to also check oil pump housing and coverand replace if damaged.OUTER AND INNER ROTOR CLEARANCEmm (in)SERVICE LIMITAB0.25 mm (.009 in)CIf clearance between inner and outer rotors exceedsthe tolerance, replace oil pump shaft assembly.Ensure to also check oil pump housingand cover and replace if damaged.If clearance between outer rotor and its bore in oilpump exceeds the tolerance, replace the completeoil pump and the PTO housing.04-07-14 LMR2004_012_04_07A.FM

Section 04 ENGINE (4-TEC)Subsection 07 (LUBRICATION SYSTEM)Using a vernier depth gauge, measure side wearas shown.InstallationFor installation, reverse the removal procedure.Pay attention to the following details.1R1503motr139A 121. Oil pump housing surface2. Vernier depth gaugeR1503motr134A 221. Screws M6 x 852. Screws M6 x 25Torque oil pump cover screws to 10 N•m (89 lbf•in).Tighten suction pump screws as per following sequenceand torque to 10 N•m (89 lbf•in). ApplyLoctite 243 (blue) on threads.8R1503motr140A 121. Oil pump outer rotor surface2. Vernier depth gaugeDifference between pump housing and outer rotorshould not exceed 0.1 mm (.004 in). If so, replacethe complete oil pump assembly.NOTE: When the axial clearance of the oil pumpshaft assembly increases, the oil pressure decreases.Check the inside of oil pump housing and its coverfor scoring or other damages and replace if damaged.76R1503motr145A2OIL FILTER BYPASSThe oil filter bypass valve is located in the PTOhousing below the oil filter.5134LMR2004_012_04_07A.FM 04-07-15

Section 04 ENGINE (4-TEC)Subsection 07 (LUBRICATION SYSTEM)RemovalRemove the PTO housing. Refer to PTO HOUSING/MAGNETO section.Remove plug screw no. 31 and pull out the oil filterbypass valve ball no. 32 and spring no. 33.OIL COOLERThe oil cooler is located below the air intake manifold.32 1R1503motr110A11. Oil coolerR1503motr146A1. Plug screw2. Compression spring3. BallInspectionInspect ball for scoring or other damages.Check compression spring for free length.RemovalRemove:– cooling hoses no. 34 and no. 35– retaining screws no. 36– oil cooler no. 3721COMPRESSION SPRING FREE LENGTHNEW NOMINAL21.5 mm (0.846 in)SERVICE LIMIT 21 mm (0.826 in)Replace parts if important wear or damage arepresent.Clean bore and threads in the PTO housing frommetal shavings and other contaminations.InstallationFor installation, reverse the removal procedure.Pay attention to the following details.Torque plug screw to 28 N•m (21 lbf•ft). ApplyLoctite 243 (blue) on threads.R1503motr147A 11. Screws2. Oil cooler04-07-16 LMR2004_012_04_07A.FM

Section 04 ENGINE (4-TEC)Subsection 07 (LUBRICATION SYSTEM)– O-rings no. 38.1R1503motr148A11. O-ringsInspectionIf O-rings are brittle, cracked or hard, replacethem.Clean both contact surfaces of oil cooler.Check and clean the oil inlet and outlet area for dirtand other contaminations.InstallationFor installation, reverse the removal procedure.Pay attention to the following details.Apply grease on O-rings.Torque oil pump cover screws to 10 N•m (89 lbf•in).Apply Loctite 243 (blue) on threads.OIL SEPARATORPressure TestRefer to ENGINE MANAGEMENT section.Removal– Remove blow-by ventilation hose no. 7.R1503motr133A1. Blow-by ventilation hose– Disconnect wiring harness from blow-by valveno. 8 and blow-by pressure switch no. 9.– Detach air intake hose from the throttle body.– Disconnect battery cables and vent tube thenremove battery. Refer to BATTERY in CHARG-ING SYSTEM section for proper procedures.– Remove retaining screws no. 42.– Place rags under cover to prevent spillage. Ifspillage occurs, clean immediately with the pulleyflange cleaner (P/N 413 711 809) to preventstains. WARNINGWear safety glasses and work in a well ventilatedarea when working with strong chemicalproducts. Also wear suitable non-absorbentgloves to protect your hands.– Remove suction pump cover with oil separatorass’y.– Remove blow-by valve no. 8 from oil separator.Refer to BLOW-BY VALVE in ENGINE MAN-AGEMENT section.– Completely disassemble oil separator ass’y.LMR2004_012_04_07A.FM 04-07-17

Section 04 ENGINE (4-TEC)Subsection 07 (LUBRICATION SYSTEM)InspectionIf O-rings and rubber rings are brittle, cracked orhard, replace them.Clean all contact surfaces of oil separator.Check and clean the oil and blow-by channels fordirt and other contaminations.InstallationFor installation, reverse the removal procedure.Pay attention to the following details.R1503motr119A 121. Screws M6 x 252. Screws M6 x 85Apply grease on O-rings and rubber rings.Torque screws to 10 N•m (89 lbf•in). Apply Loctite243 (blue) on threads.04-07-18 LMR2004_012_04_07A.FM

Subsection 08Section 04 ENGINE (4-TEC)(CYLINDER HEAD AND VALVES)CYLINDER HEAD AND VALVES 0NOTE: For cylinder head removal, it is not necessary to remove engine from vehicle.3110 N•m(89 lbf•in)Engine oil4105Grease KlueberIsoflex Topas NB52Loctite2436 N•m(53 lbf•in)141310 N•m 15(89 lbf•in)11Engineoil2412 25222128293010237918 N•m(159 lbf•in)10 N•m(89 lbf•in)21610 N•m(89 lbf•in)Loctite243208620 N•m (177 lbf•in) + 90°EngineoilLoctite24310 N•m(89 lbf•in)Loctite2436 N•m(53 lbf•in)18 N•m(159 lbf•in)171840 N•m (30 lbf•ft)+ 120° + 90°R1503motr43SEngine oilEngine oil2627Loctite 24310 N•m (89 lbf•in)19LMR2004-013_04_08A.FM 04-08-1

Section 04 ENGINE (4-TEC)Subsection 08 (CYLINDER HEAD AND VALVES)GENERALNOTE: This procedure to be performed for eachengine.NOTE: When diagnosing an engine problem, alwaysperform a cylinder leak test. This will helppin-point a problem. Refer to the instructions includedwith your leak tester and LEAK TEST sectionfor procedures.Always place the vehicle on level surface.NOTE: For a better understanding, the followingillustrations are taken with engine out of vehicle.To perform the following instructions, it is not necessaryto remove engine from vehicle.Always disconnect the negative wire from the batterybefore working on the engine.Even if the removal of many parts is not necessaryto reach another part, it is recommended to removethese parts in order to check them.For installation, use the torque values and Loctiteproducts as mentioned. Clean threads before usingLoctite product when installing screws.When disassembling parts that are duplicated inthe engine, (e.g.: valves, bushings), it is stronglyrecommended to note their position (cylinder 1, 2or 3) and to keep them as a “group”. If you find adefective component, it would be much easier tofind the cause of the failure among its group ofparts (e.g.: you found a worn valve guide. A bentspring could be the cause and it will be easy toknow which one among the springs is the causeto replace it if you grouped them at disassembly).Besides, since used parts have matched togetherduring the engine operation, they will keep theirmatched fit when you reassemble them togetherwithin their “group”.SPARK PLUGRemovalRemove fuel rail cover from engine.Unplug the single-spark ignition coil connector onthe spark plug you need to remove.Remove the single-spark ignition coil no. 1.Clean spark plug and single-spark ignition coil areabefore disassembly.Unscrew spark plug no. 2 then use the single-sparkignition coil to take spark plug out of spark plug hole.R1503motr44A1. Single-spark ignition coil2. Spark plugInspectionCheck spark plug and single-spark ignition coil condition(refer to ENGINE MANAGEMENT SYSTEM).Installation2For installation, reverse the removal procedure.Pay attention to the following details.Check spark plug gap.Place spark plug into single-spark ignition coil,screw spark plug then remove the single-spark ignitioncoil. Torque spark plug. Reinstall the singlesparkignition coil.NOTE: Prior to inserting the ignition coil to its location,apply some BOMBARDIER LUBE lubricantaround the seal area that touches the spark plughole. After installation, ensure the seal seats properlywith the engine top surface.104-08-2 LMR2004-013_04_08A.FM

Subsection 08Section 04 ENGINE (4-TEC)(CYLINDER HEAD AND VALVES)VALVE COVERRemovalRemove:– valve cover shield no. 3– valve cover screws no. 4InstallationFor installation, reverse the removal procedure.NOTE: Install the valve cover screws according tofollowing sequence.31 517R1503motr81AR1503motr159A8 2 4 61. Valve cover screws– valve cover no. 5 and profile sealing ring no. 6.R1503motr82A1. Valve cover2. Profile sealing ringInspection1Check the profile sealing ring on the valve coverand the rubber bushing on the valve cover screwsif they are brittle, cracked or hard. If so, replace theprofile sealing ring or the valve cover screw accordingly.2Torque screws to 10 N•m (89 lbf•in).ROCKER ARMRemovalLock crankshaft with crankshaft locking tool(P/N 529 035 821), refer to CRANKSHAFT LOCK-ING in ENGINE BLOCK section.Remove:– spark plug– valve cover– spark plug tube no. 71R1503motr83A1. Spark plug tubeLMR2004-013_04_08A.FM 04-08-3

Section 04 ENGINE (4-TEC)Subsection 08 (CYLINDER HEAD AND VALVES)– rocker arm shaft screws no. 8. Discard screws.1InspectionSpark Plug TubeCheck seals on spark plug tube. If seals are brittle,cracked or hard, replace spark plug tube.R1503motr93B1. Rocker arm shaft screws– rocker arm shaft no. 9 with rocker arm assembly(exhaust side no. 10 and intake side no. 11).312 13R1503motr86A1. Spark plug tube2. Seal to the valve cover3. Seal to the cylinder headRocker ArmInspect each rocker arm for cracks and scored frictionsurfaces. If so, replace rocker arm assembly.Check the rocker arm rollers for free movement,wear and excessive radial play. Replace rockerarm assembly as necessary.R1503motr84A 21. Rocker arm shaft2. Rocker arms (exhaust side)3. Rocker arm (intake side)1AR1503motr87A1. Rocker arm (intake side)2. RollerA. Bore for rocker arm shaft12R1503motr85A1. Oil supply from the camshaft to the rocker arm shaft, then to therocker arms and finally to the valve adjustment04-08-4 LMR2004-013_04_08A.FM

Subsection 08Section 04 ENGINE (4-TEC)(CYLINDER HEAD AND VALVES)Rocker Arm ShaftCheck for scored friction surfaces, if so, replaceparts.Measure rocker arm shaft diameter.ROCKER ARM SHAFT DIAMETERNEW MINIMUM19.980 mm (.7866 in)R1503motr88A 2A1NEW MAXIMUMSERVICE LIMIT20.007 mm (.7877 in)19.965 mm (.7860 in)1. Rocker arm (exhaust side)2. RollerA. Bore for rocker arm shaftMeasure rocker arm bore diameter. If diameter isout of specification, change the rocker arm assembly.R1503motr90AAROCKER ARM BORE DIAMETERNEW MINIMUM20.007 mm (.7877 in)NEW MAXIMUM 20.020 mm (.7881 in)SERVICE LIMIT20.035 mm (.7887 in)Press the hydraulic lifter with your thumb. If thehydraulic lifter groove disappears inside rockerarm casting, replace rocker arm assembly. Liftermust turn freely in rocker arm bore. Otherwise,replace.A. Measure rocker arm shaft diameter hereAny area worn excessively will require parts replacement.InstallationFor installation, reverse the removal procedure.Pay attention to the following details.Apply engine oil on rocker arm shaft.IMPORTANT: The rocker arm shaft can only beinstalled in one specific position. Therefore crankshaftas well as camshaft has to be positionedwith their locking pins when the piston of cylinderno. 3 is on ignition TDC. Refer to CRANKSHAFTLOCKING in ENGINE BLOCK section for crankshaftand the following for the camshaft locking.1R1503motr89A1. Hydraulic lifter grooveLMR2004-013_04_08A.FM 04-08-5

Section 04 ENGINE (4-TEC)Subsection 08 (CYLINDER HEAD AND VALVES)Use camshaft locking tool (P/N 529 035 839). Rotatecamshaft so that tool can be pushed in camshafthole and lock camshaft in place.211R1503motr91AR1503motr111A1. Camshaft locking toolThen, the camshaft sprocket lines should be linedup as shown in the following illustration.111. Rocker arm shaft2. Rocker arm shaft notchesInstall NEW rocker arm shaft screws no. 8. Torqueas per following procedure:CAUTION: This assembly uses stretch screws. Asthe screws have been stretched from the previousinstallation, it is very important to use new screwsat assembly. Failure to replace screws and tostrictly follow the torque procedure may causescrews to loosen and lead to engine damage.– Torque screws at first to 10 N•m (89 lbf•in) accordingto following sequence.6521 3 4R1503motr95A1. Position linesPosition the rocker arm shaft with the notches ontop.R1503motr93A– Torque screws to 20 N•m (177 lbf•in).– Finish tightening screws turning an additional90° rotation with a torque angle gauge.04-08-6 LMR2004-013_04_08A.FM

Subsection 08Section 04 ENGINE (4-TEC)(CYLINDER HEAD AND VALVES)12InstallationFor installation, reverse the removal procedure.Pay attention to the following details.Using the camshaft locking tool (P/N 529 035 839),lock camshaft on TDC position.1R1503motr92A1. Rocker arm shaft screw2. Torque angle gaugeCAMSHAFT TIMING GEARNOTE: Although it is not necessary to positioncrankshaft to TDC for disassembly, it is a good practiceto do it, as a troubleshooting step, to know beforedisassembly if valve timing was appropriate.RemovalLock crankshaft with crankshaft locking tool (P/N 529035 821), refer to CRANKSHAFT LOCKING in EN-GINE BLOCK section.Remove:– valve cover– chain tensioner. Refer to CHAIN TENSIONERREMOVAL in ENGINE BLOCK section– chain guide no. 12– Allen screws no. 13– camshaft timing gear no. 14.NOTE: Secure timing chain no. 15 with a retainingwire.InspectionCheck camshaft timing gear for wear or deterioration.If gear is worn or damaged, replace it as a set(camshaft timing gear and timing chain).For crankshaft timing gear, refer to ENGINE BLOCKsection.R1503motr94A1. Camshaft locking tool2. Camshaft on TDC positionInstall the camshaft timing gear with the writingvisible, i.e. to be able to see the position lineswhen looking from outside of engine.122R1503motr97A1. Good (with 1503 aligned)2. NeverInstall timing chain. Refer to ENGINE BLOCK section.LMR2004-013_04_08A.FM 04-08-7

Section 04 ENGINE (4-TEC)Subsection 08 (CYLINDER HEAD AND VALVES)Ensure chain guides are in place.Loosely install screws.Install chain tensioner.Tighten screws and torque to 10 N•m (89 lbf•in).Remove locking tools.CAUTION: Crankshaft and camshaft must belocked on TDC position to place camshaft timinggear and timing chain in the proper position.To double check, take a look at the timinggear lines. They must be parallel to the cylinderhead surface.Remove:– exhaust manifold (refer to EXHAUST MANIFOLDREMOVAL elsewhere in this section)– engine coolant outlet hose1211R1503motr253AR1503motr95A1. Position linesCAUTION: Ensure to remove locking tools whenfinished.TIMING CHAINRefer to ENGINE BLOCK section.TYPICAL1. Coolant hose2. Blow-by ventilation hose– coolant hose– chain tensioner (refer to CHAIN TENSIONER RE-MOVAL in ENGINE BLOCK section)– valve cover shield– valve cover and profile sealing ring(see VALVE COVER REMOVAL above)– camshaft timing gear– cylinder head screws M6 no. 16CYLINDER HEADRemovalLock crankshaft with crankshaft locking tool(P/N 529 035 821), refer to CRANKSHAFT LOCK-ING in ENGINE BLOCK section.Drain coolant (refer to COOLING SYSTEM).Disconnect coolant temperature and cam positionsensors (CTS and CAPS).1R1503motr98A1. Cylinder head screws M604-08-8 LMR2004-013_04_08A.FM

Subsection 08Section 04 ENGINE (4-TEC)(CYLINDER HEAD AND VALVES)– cylinder head screws M11 no. 17 retaining cylinderhead to engine block.1Install cylinder head screws M11 no. 17. Torquescrews as per following procedure.CAUTION: This assembly uses stretch screws.As the screws have been stretched from the previousinstallation, it is very important to measureeach screw at assembly. If screw is out of specification,replace. Failure to replace screws and tostrictly follow the torque procedure may causescrews to loosen and lead to engine damage.CYLINDER HEAD SCREW M11SERVICE LIMIT148.5 mm (5.846 in)R1503motr99A1. Cylinder head screws M11Pull up cylinder head no. 18.Remove gasket no. 19.CleaningRemove carbon deposits from combustion chamber,exhaust port and piston top.Torque screws according to following sequence.First torque to 40 N•m (30 lbf•ft).Then tighten screws turning an additional 120° rotationwith a torque angle gauge and finish tighteningwith a 90° rotation. Torque screws no. 16 to10 N•m (89 lbf•in).21InspectionCheck for cracks between valve seats, if so, replacecylinder head.Check mating surface between cylinder and cylinderhead for contamination. If so, clean both surfaces.InstallationFor installation, reverse the removal procedure.Pay attention to the following details.Ensure dowel pins are in place.Install new cylinder head gasket.CAUTION: Each installation of the cylinder headrequires a new cylinder head gasket. Using agasket twice will cause engine damage, even ifthe engine had not run.R1503motr100A1. Cylinder head screws M112. Angle torque wrenchRemove crankshaft locking tool then install plugwith sealing ring.LMR2004-013_04_08A.FM 04-08-9

Section 04 ENGINE (4-TEC)Subsection 08 (CYLINDER HEAD AND VALVES)CAMSHAFTRemovalRemove:– valve cover– rocker arms– chain tensioner (refer to CHAIN TENSIONERREMOVAL in ENGINE BLOCK section)– camshaft timing gear– camshaft lock no. 20– camshaft no. 21.R1503motr101A1. Camshaft lock2. CamshaftInspection2Check each lobe and bearing journal of camshaftfor scoring, scuffing, cracks or other signs of wear.Measure camshaft bearing journal diameter andlobe height using a micrometer.Measure clearance between both ends of camshaftand cylinder head.D A B A C C A B A C C A B A C1CAMSHAFT LOBE - EXHAUST VALVENEW MINIMUM31.699 mm (1.248 in)NEW MAXIMUM 31.809 mm (1.252 in)SERVICE LIMIT31.670 mm (1.247 in)CAMSHAFT LOBE - INTAKE VALVENEW MINIMUM31.480 mm (1.239 in)NEW MAXIMUM 31.590 mm (1.244 in)SERVICE LIMIT31.450 mm (1.238 in)CAMSHAFT BEARING JOURNALNEW MINIMUM 39.892 mm (1.5705 in)NEW MAXIMUM 39.905 mm (1.5711 in)SERVICE LIMIT39.860 mm (1.5693 in)CAMSHAFT BEARING JOURNAL -ENGINE FRONTNEW MINIMUM24.939 mm (.9818 in)NEW MAXIMUM 24.960 mm (.9826 in)SERVICE LIMIT24.910 mm (.9807 in)CAMSHAFT BOREMEASURED IN DIAMETERNEW MINIMUM 40.000 mm (1.5748 in)NEW MAXIMUM 40.016 mm (1.5754 in)SERVICE LIMIT40.050 mm (1.5767 in)CAMSHAFT BORE - ENGINE FRONTMEASURED IN DIAMETERNEW MINIMUM25.000 mm (.9842 in)NEW MAXIMUM 25.013 mm (.9848 in)SERVICE LIMIT25.050 mm (.9862 in)Replace parts that are not within specifications.InstallationFor installation, reverse the removal procedure.Pay attention to the following details.Grease the camshaft bearing journals well by usingthe grease Klueber Isoflex (P/N 293 550 021)or a similar product.R1503motr102AA. Camshaft lobe (exhaust valves)B. Camshaft lobe (intake valves)C. Camshaft bearing journalD. Camshaft bearing journal — engine front04-08-10 LMR2004-013_04_08A.FM

Subsection 08Section 04 ENGINE (4-TEC)(CYLINDER HEAD AND VALVES)Install camshaft then place the camshaft lock no. 20in the slot.121R1503motr101B1. Camshaft lock positionFor other parts, refer to proper installation procedure.VALVE SPRINGRemovalRemove:– rocker arms– cylinder head.Compress valve springs no. 22 and no. 23. Usevalve spring compressor clamp (P/N 529 035 724)and valve spring compressor cup (P/N 529 035725). WARNINGAlways wear safety glasses when disassemblingvalve springs. Be careful when unlockingvalves. Components could fly away becauseof the strong spring preload.R1503motr103A1. Valve spring compressor clamp2. Valve spring compressor cupR1503motr104ALOCATE VALVE SPRING COMPRESSOR CLAMP IN CENTER OFTHE VALVELMR2004-013_04_08A.FM 04-08-11

Section 04 ENGINE (4-TEC)Subsection 08 (CYLINDER HEAD AND VALVES)Remove valve cotters no. 24.Withdraw valve spring compressor, valve springretainer no. 25 and valve springs.123InstallationFor installation, reverse the removal procedure.Pay attention to the following details.Colored area of the valve spring must be placedon top.NOTE: Valve cotters must be properly engaged invalve stem grooves.1R1503motr105A1. Valve spring retainer2. Inner valve spring3. Outer valve springInspectionCheck valve springs for rust, corrosion or other visibledamages. If so, replace faulty valve springs.Check valve springs for free length and straightness.Replace valve springs if not within specifications.R1503motr105B1. Position of the valve springVALVERemovalRemove valve spring.Push valve stem then pull valves no. 26 andno. 27 out of valve guides.1R610motr122AA2A. Valve spring lengthOUTER VALVE SPRING FREE LENGTHNEW NOMINAL45.45 mm (1.789 in)SERVICE LIMIT43 mm (1.693 in)INNER VALVE SPRING FREE LENGTHNEW NOMINAL41.02 mm (1.615 in)SERVICE LIMIT38.8 mm (1.499 in)R1503motr106A1. Intake valve 38 mm2. Exhaust valve 31 mm04-08-12 LMR2004-013_04_08A.FM

Subsection 08Section 04 ENGINE (4-TEC)(CYLINDER HEAD AND VALVES)Remove valve stem seal no. 28 with special plierssuch as Snap-On YA 8230.AR610motr126AA. Valve stem diameterR610motr125AInspectionValve Stem SealInspection of valve stem seals is not needed becausenew seals should always be installed whenevercylinder head is removed.ValveInspect valve surface, check for abnormal stemwear and bending. If so, replace by a new one.Valve Stem and Valve Guide ClearanceMeasure valve stem and valve guide in three places,using a micrometer and a small bore gauge.NOTE: Clean valve guide to remove carbon depositsbefore measuring.Change valve if valve stem is out of specificationor has other damages such as wear or friction surface.VALVE STEM DIAMETER mm (in)NEW MINIMUMExhaust5.946 mm (.2341 in)Intake5.961 mm (.2347 in)NEW MAXIMUMExhaust5.960 mm (.2346 in)Intake5.975 mm (.2352 in)SERVICE LIMITExhaust5.93 mm (.233 in)IntakeReplace valve guide if it is out of specification orhas other damages such as wear or friction surface.VALVE GUIDE DIAMETER mm (in)NEW MINIMUMExhaust5.994 mm (.2359 in)IntakeNEW MAXIMUMExhaust6.018 mm (.2369 in)IntakeSERVICE LIMITExhaust6.060 mm (.2386 in)IntakeLMR2004-013_04_08A.FM 04-08-13

Section 04 ENGINE (4-TEC)Subsection 08 (CYLINDER HEAD AND VALVES)Valve Face and Seat23If valve seat contact width is too wide or has darkspots, replace the cylinder head.ABR1503motr107A1. Valve seat2. Exhaust valve contaminated area3. Valve face (contact surface to valve seat)1Check valve face and seat for burning or pittingsand replace valve or cylinder head if there aresigns of damage.Ensure to seat valves properly. Apply some lappingcompound to valve face and work valve on itsseat with a lapping tool.Measure valve face contact width.NOTE: The location of contact area should be incenter of valve seat.Measure valve seat width, using a caliper.V01C1HAA. Valve face contact widthB. Valve seat contact widthInstallationFor installation, reverse the removal procedure.Pay attention to the following details.Install thrust washer no. 30, valve spring guideno. 29 then valve stem seal no. 28.3VALVE SEAT CONTACT WIDTH mm (in)NEWExhaustIntakeExhaustIntake1.25 to 1.55 mm(.049 to .061 in)1.10 to 1.30 mm(.043 to .051 in)SERVICE LIMIT2 mm (.078 in)1.8 mm (.07 in)R1503motr108A1. Thrust washer2. Valve spring guide3. Valve stem seal2104-08-14 LMR2004-013_04_08A.FM

Subsection 08Section 04 ENGINE (4-TEC)(CYLINDER HEAD AND VALVES)Apply engine oil on valve stem and install it.CAUTION: Be careful when valve stem is passedthrough sealing lips of valve stem seal.1R1503motr108B1. Sealing lips of valve stem sealTo ease installation of cotters, apply oil or greaseto them so that they remain in place while releasingthe spring.After spring is installed, ensure it is properlylocked by tapping on valve stem end with a softhammer so that valve opens and closes a fewtimes.CAUTION: An improperly locked valve springwill cause engine damage.LMR2004-013_04_08A.FM 04-08-15

Section 04Subsection 09ENGINE (4-TEC)(ENGINE BLOCK)ENGINE BLOCK 024 N•m(18 lbf•ft)Loctite 243Loctite 24324 N•m(18 lbf•ft)Engineoil18 N•m(159 lbf•in)221810 N•m(89 lbf•in)19Engineoil2021GreaseKlueber Isoflex Topas NB52 Grease10 N•m(89 lbf•in)Loctite 243EngineoilLoctite 243Loctite 243Engineoil161718 N•m(159 lbf•in)Loctite 24324 N•m(18 lbf•ft)24 N•m(18 lbf•ft)Engineoil3Loctite 24318 N•m(159 lbf•in)10 N•m(89 lbf•in)Loctite 2432124 N•m(18 lbf•ft)724 N•m(18 lbf•ft)40 N•m 55 N•m(30 lbf•ft)+(41 lbf•ft)R1503motr01SLMR2004_014_04_09A.FM 04-09-1

Section 04 ENGINE (4-TEC)Subsection 09 (ENGINE BLOCK)89Engineoil108EngineoilEngineoilEngineoilEngineoil260 N•m(191 lbf•ft)Loctiteanti-seizeEngineoil4Engineoil42312Engineoil6Engineoil1145 N•m(33 lbf•ft) + 90°13Engineoil6Engineoil155EngineoilEngineoilEngineoilEngineoil1415R1503motr02S04-09-2 LMR2004_014_04_09A.FM

Section 04Subsection 09ENGINE (4-TEC)(ENGINE BLOCK)GENERALNOTE: This procedure to be performed for eachengine.When disassembling parts that are duplicated in theengine, (e.g.: pistons, connecting rods etc.), it isstrongly recommended to note their position (Cylinder1, 2 or 3) and to keep them as a “group”. If youfind a defective component, it would be much easierto find the cause of the failure among its groupof parts (e.g.: you found a worn valve guide. A bentspring could be the cause and it will be easy to knowwhich one among the springs is the cause in orderto replace it if you grouped them at disassembly).Besides, since used parts have matched togetherduring engine operation, they will keep theirmatched fit when you reassemble them togetherwithin their “group”.CRANKSHAFT LOCKINGRemove:– air intake manifold (refer to AIR INTAKE MANI-FOLD REMOVAL in ENGINE section)– fuel rail cover– spark plugs– screw plug.R1503motr04A21R1503motr03A1. ScrewdriverIn this position, the crankshaft can be locked byusing crankshaft locking tool (P/N 529 035 821).When finished, reinstall all removed parts.CRANKSHAFTRemovalRemove:– engine oil (refer to OIL CHANGE in LUBRICA-TION section)– engine from vehicle(refer to REMOVAL AND INSTALLATION)– cylinder head (refer to CYLINDER HEAD RE-MOVAL in CYLINDER HEAD section)– PTO housing (refer to PTO HOUSING REMOV-AL in PTO HOUSING/MAGNETO section)– starter gear (refer to STARTER GEAR REMOV-AL in PTO HOUSING/MAGNETO section)– starter drive ass’y– oil suction pump with oil separator ass’y(refer to SUCTION PUMP REMOVAL in LUBRI-CATION section)– engine mounting brackets11. Screw plug2. Gasket ringPut a screwdriver or similar device into the sparkplug hole of cylinder # 3 and feel when the pistonreaches TDC.LMR2004_014_04_09A.FM 04-09-3

Section 04 ENGINE (4-TEC)Subsection 09 (ENGINE BLOCK)– oil tank screw plugs no. 1 with O-ring no. 21NOTE: Before removing the connecting rod bearingcaps, mark them to remember the right positionwhen reassembling.R1503motr05AENGINE UPSIDE DOWN1. Oil tank screw plug with O-ring– engine block screws no. 3 and no. 7R1503motr07A 11. Mark on connecting rod– thrust washers no. 411R1503motr06ABOTTOM VIEW OF ENGINE1. Screws– bottom engine block half– connecting rod screwsR1503motr09A11. Thrust washerR1503motr08A1. Connecting rod screws04-09-4 LMR2004_014_04_09A.FM

Section 04Subsection 09ENGINE (4-TEC)(ENGINE BLOCK)– crankshaft no. 5.112R1503motr10A1. CrankshaftInspectionReplace crankshaft if the gears are worn or otherwisedamaged.2R1503motr12A1. Crankshaft2. Feeler gaugeCONNECTING ROD BIG ENDmm (in)NEW MINIMUMNEW MAXIMUMSERVICE LIMIT0.150 mm (.006 in)0.302 mm (.012 in)0.5 mm (.02 in)Crankshaft Radial PlayMeasure all crankshaft journals. Compare to insidediameter of crankshaft bushings (elsewhere in thissection).1R1503motr11A11. Balancer gear2. Crankshaft timing gearConnecting Rod Big End Axial PlayUsing a feeler gauge, measure distance betweenbutting face of connecting rod and crankshaft counterweight.If the distance exceeds specified tolerance,replace the worn part.2R1503motr13A1. Micrometer2. Crankshaft area for bushingLMR2004_014_04_09A.FM 04-09-5

Section 04 ENGINE (4-TEC)Subsection 09 (ENGINE BLOCK)CRANKSHAFT JOURNAL DIAMETERmm (in)NEW MINIMUMNEW MAXIMUMSERVICE LIMIT49.91 mm (1.9650 in)50.01 mm (1.9689 in)49.88 mm (1.9637 in)CRANKSHAFT JOURNAL RADIAL CLEARANCEmm (in)SERVICE LIMIT0.07 mm (.0028 in)InstallationFor installation, reverse the removal procedure.Pay attention to following details.NOTE: Before installing the crankshaft, makesure that the timing chain is on the crankshaft andthe chain tension guide has been installed first.Those parts cannot be installed as soon as thecrankshaft is in place.CAUTION: Crankshaft must be aligned with balanceshaft. Align grooves on crankshaft and balanceshaft.Crankshaft PinMeasure all crankshaft pin diameters. Compare toinside diameter of connecting rod bushings (elsewherein this section).1 2R1503motr17A 1 2R1503motr14A1. Micrometer2. Crankshaft pin area for bushingCRANKSHAFT PIN DIAMETERmm (in)NEW MINIMUM 45.032 mm (1.7729 in)NEW MAXIMUM 45.048 mm (1.7735 in)SERVICE LIMIT 45.029 mm (1.7728 in)1. Groove on balance shaft2. Groove on crankshaftFor correct installation of the connecting rods referto CONNECTING ROD INSTALLATION elsewherein this section.CAUTION: It is absolutely necessary to followthis procedure. Otherwise severe engine damagecan occur.CAUTION: Never forget thrust washers no. 4 foraxial adjustment on crankshaft center.CRANKSHAFT PIN RADIAL CLEARANCEmm (in)SERVICE LIMIT0.09 mm (.0035 in)04-09-6 LMR2004_014_04_09A.FM

Section 04Subsection 09ENGINE (4-TEC)(ENGINE BLOCK)Insert thrust washers as soon as crankshaft is inplace according to following illustration.Install the crankshaft cover before mounting theengine bracket. Put some oil on O-ring and pressthe cover in. The crankshaft cover has to be evenwith the engine block surface.11R1503motr09ATHRUST WASHER INSERT DIRECTION1. Thrust washerCAUTION: Thrust washers must be even with theengine block sealing surface.12R1503motr19A 21. O-ring2. Crankshaft coverCAUTION: Install crankshaft locking tool (P/N 529035 821) right away to put crankshaft in TDC positionbefore installing the camshaft and rockers(refer to CYLINDER AND HEAD).1R1503motr16A1. Thrust washer2. Sealing surfaceInstall lower engine block half. Refer to ENGINEBLOCK ASSEMBLY elsewhere in this section forproper procedure to clean surfaces, apply Loctite5910 and proper torquing sequence.R1503motr18A1. Crankshaft locking toolLMR2004_014_04_09A.FM 04-09-7

Section 04 ENGINE (4-TEC)Subsection 09 (ENGINE BLOCK)TIMING CHAINInspectionCheck timing chain on camshaft timing gear forexcessive radial play.Check chain condition for wear and rollers condition.CHAIN TENSIONERRemovalNOTE: Removal of the air intake manifold allowseasier access to the chain tensioner, but is notnecessary. Refer to AIR INTAKE MANIFOLD RE-MOVAL in INTAKE section.Remove:– chain tensioner screw plug no. 18 with gasketring no. 19– chain tensioner no. 20.R610motr201A1321. Timing chainIf chain is excessively worn or damaged, replaceit as a set (camshaft timing gear and timing chain).RemovalRemove:– engine oil (refer to OIL CHANGE in LUBRICA-TION section)– engine from vehicle(refer to REMOVAL AND INSTALLATION)– cylinder head (refer to CYLINDER HEAD RE-MOVAL in CYLINDER HEAD section)– PTO housing (refer to PTO HOUSING REMOV-AL in PTO HOUSING/MAGNETO section)– crankshaft (refer to CRANKSHAFT REMOVALelsewhere in this section)– timing chain.InstallationThe installation is essentially the reverse of the removalprocedure but, pay attention to the followingdetails.Ensure to perform proper valve timing. Lock crankshaftand camshaft at TDC (refer to CYLINDERHEAD).Install chain, then install chain tensioner.CAUTION: Improper valve timing will damageengine components.R1503motr39A 11. Screw plug2. Gasket ring3. Chain tensionerInspectionCheck chain tensioner for excessive wear or cracks.Also check free movement of the chain tensionerpiston.InstallationThe installation is essentially the reverse of the removalprocedure but, pay attention to the followingdetails.Torque chain tensioner screw plug to 18 N•m(159 lbf•in).BALANCER SHAFTRemovalRemove:– engine oil (refer to OIL CHANGE in LUBRICA-TION section)04-09-8 LMR2004_014_04_09A.FM

Section 04Subsection 09ENGINE (4-TEC)(ENGINE BLOCK)– engine from vehicle(refer to REMOVAL AND INSTALLATION)– cylinder head (refer to CYLINDER HEAD RE-MOVAL in CYLINDER HEAD section)– PTO housing (refer to PTO HOUSING REMOV-AL in PTO HOUSING/MAGNETO section)– starter gear (refer to STARTER GEAR REMOV-AL in PTO HOUSING/MAGNETO section)– starter drive ass’y– oil suction pump with oil separator ass’y(refer to SUCTION PUMP REMOVAL in LUBRI-CATION section)– engine mounting brackets– oil tank screw plugs no. 1 with O-ring no. 21R1503motr20A1. Thrust washer– balance shaft.1R1503motr05AENGINE UPSIDE DOWN1. Oil tank screw plug with O-ring– engine block screws no. 3InspectionCheck balancer shaft and replace if damaged.If the gear on the balancer shaft is damaged, replacebalancer shaft.Check gear(s) on the crankshaft at the same timeand replace crankshaft if necessary (refer to CRANK-SHAFT above).Balance Shaft Bushing Seat PlayMeasure all balance shaft bushing seats. Compareto inside diameter of balance shaft bushings (elsewherein this section).112R1503motr06A1. Screws– bottom engine block half– thrust washers no. 6R1503motr23A1. Micrometer2. Balance shaft area for bushingsLMR2004_014_04_09A.FM 04-09-9

Section 04 ENGINE (4-TEC)Subsection 09 (ENGINE BLOCK)BALANCE SHAFT SEAT DIAMETERmm (in)NEW MINIMUMNEW MAXIMUMSERVICE LIMIT31.984 mm (1.2592 in)32.000 mm (1.2598 in)31.960 mm (1.2583 in)1BALANCE SHAFT SEAT RADIAL CLEARANCEmm (in)SERVICE LIMIT0.07 mm (.0028 in)InstallationFor installation, reverse the removal procedure.Pay attention to following detail.CAUTION: Balance shaft must be aligned withcrankshaft. Align grooves on crankshaft andbalance shaft.R1503motr20BTHRUST WASHER INSERT DIRECTION1. Thrust washerCAUTION: Thrust washers must be even withthe engine block sealing surface.21R1503motr17A 1 21. Groove on balance shaft2. Groove on crankshaftCAUTION: Never forget thrust washers no. 6for axial adjustment on balance shaft PTO side.Insert thrust washers as soon as balance shaft isin place according to following illustration.R1503motr22A1. Thrust washer2. Sealing surfaceInstall lower engine block half. Refer to ENGINEBLOCK ASSEMBLY elsewhere in this section forproper procedure to clean surfaces, apply Loctite5910 and the proper torquing sequence.04-09-10 LMR2004_014_04_09A.FM

Section 04Subsection 09ENGINE (4-TEC)(ENGINE BLOCK)Install the crankshaft cover before mounting theengine bracket. Put some oil on O-ring and pressthe cover in. The crankshaft cover has to be evenwith the engine block surface.1R1503motr19A 21. O-ring2. Crankshaft coverCAUTION: Install crankshaft locking tool (P/N 529035 821) right away to put crankshaft in TDC positionbefore installing the camshaft and rockers(refer to CYLINDER AND HEAD).1ENGINE BLOCKRemovalRemove:– engine oil(refer to OIL CHANGE in LUBRICATION section)– engine from vehicle(refer to REMOVAL AND INSTALLATION)– cylinder head (refer to CYLINDER HEAD REMOV-AL in CYLINDER HEAD section)– PTO housing (refer to PTO HOUSING REMOVALin PTO HOUSING/MAGNETO section)– starter gear (refer to STARTER GEAR REMOVALin PTO HOUSING/MAGNETO section)– starter drive ass’y– oil suction pump with oil separator ass’y(refer to SUCTION PUMP REMOVAL in LUBRI-CATION section)– balance shaft (refer to BALANCE SHAFT REMOV-AL elsewhere in this section)– crankshaft (refer to CRANKSHAFT REMOVALelsewhere in this section)– piston with connecting rod (refer to PISTON RE-MOVAL elsewhere in this section).BushingsWhen bushings need to be removed from the engineblock, mark them to identify the correct positionat installation. See the following illustration foran example:1R1503motr18A1. Crankshaft locking toolR1503motr37A 21. Mark on balance shaft bushings2. Mark on crankshaft bushingsLMR2004_014_04_09A.FM 04-09-11

Section 04 ENGINE (4-TEC)Subsection 09 (ENGINE BLOCK)Starter Drive BearingCheck bearing no. 21 of starter drive assemblyno. 22 in engine block and replace if damaged.Cylinder TaperMeasure cylinder bore and if it is out of specifications,rehone cylinder sleeve and replace pistonass’y with first oversize.NOTE: It is not necessary to have all cylinders rehonedif they are not all out of specification. Mixedstandard size and oversize cylinders are allowed.Measure cylinder bore at 3 recommended positions.See the following illustration.2A1BR1503motr40A 131. Bearing of starter drive assemblyStarter drive bearing can be easily removed fromlower crankcase half using the following suggestedtool or equivalent:– Snap-on hammer puller including:– handle CJ93-1– hammer CJ125-6– claws CJ93-4.R1503motr24A1. First measuring diameter2. Second measuring diameter3. Third measuring diameterA. 60 mm (2.362 in)B. 110 mm (4.331 in)CYLINDER TAPER IN DIAMETERmm (in)NEW MAXIMUMSERVICE LIMIT0.038 mm (.001 in)0.090 mm (.004 in)F01J0ZAClose puller claws so that they can be inserted inend bearing. Holding claws, turn puller shaft clockwiseso that claws open and become firmly tightagainst bearing.Slide puller hammer outwards and tap puller end.Retighten claws as necessary to always maintainthem tight against bearing. Continue this way untilbearing completely comes out.Distance between measurements should not exceedthe service limit mentioned above.Cylinder Out of RoundMeasure cylinder diameter in piston axis directionfrom top of cylinder. Take an other measurement90° from first one and compare.NOTE: Take the same measuring points like describedin CYLINDER TAPER above.InspectionCylinderCheck cylinder for cracks, scoring and wear ridgeson the top and bottom of the cylinder. If so, replacecylinder.04-09-12 LMR2004_014_04_09A.FM

Section 04Subsection 09ENGINE (4-TEC)(ENGINE BLOCK)CRANKSHAFT BUSHING INSIDE DIAMETERmm (in)SERVICE LIMIT50.1 mm (1.9724 in)ABR1503motr25AA. Perpendicular to crankshaft axisB. Parallel to crankshaft axisCYLINDER OUT OF ROUNDmm (in)NEW MAXIMUMSERVICE LIMIT0.008 mm (.0003 in)0.015 mm (.0006 in)R1503motr34A 1ENGINE UPSIDE DOWN1. Radial gaugeBushingsTo measure the wear of the crankshaft bushingsno. 13 and no. 14 and balance shaft bushingsno. 15, both engine block halves with OLD bushingshave to be screwed together according totightening procedure described below.Measure the inside diameter of the bushings witha radial gauge.BALANCE SHAFT BUSHING INSIDE DIAMETERmm (in)SERVICE LIMIT32.11 mm (1.2642 in)Replace bushings if they are out of specifications.Oil Spray NozzlesRemove oil spray nozzle no. 16 and banjo screwno. 17 from engine block.112R1503motr33AENGINE UPSIDE DOWN1. Radial gaugeR1503motr38A1. Banjo screw2. Oil spray nozzleLMR2004_014_04_09A.FM 04-09-13

Section 04 ENGINE (4-TEC)Subsection 09 (ENGINE BLOCK)Check free movement of ball inside the banjoscrew. Clean nozzle and banjo screw from dirt anddebris.InstallationFor installation, reverse the removal procedure.Pay attention to the following details.Torque oil spray nozzle to 18 N•m (159 lbf•in).To install starter drive bearing no. 21 of starterdrive assembly, use pusher (P/N 290 876 502) andhandle (P/N 420 877 650).Bushings have to be even with the engine block splitsurface and their protrusions have to fit in thenotched areas in the engine block seat.11R1503motr36AF06D32A1. Handle2. PusherUse NEW bushings when diameters are out ofspecification.If OLD bushings can be used again, make surethey are at the same position as they were before.Put bushings correctly in place. Top crankshaft bushinghalves have a bore which has to be placed in theupper engine block.123R1503motr35A21. Bushing protrusion in engine block notchApply engine oil on all bushings, in the bottom areaof the cylinder bore and also on the band of thepiston ring compressor tool.For proper installation of pistons, refer to PISTONINSTALLATION elsewhere in this section.NOTE: Before installing the crankshaft, makesure that the timing chain is on the crankshaft andthe chain tension guide has been installed first.Those parts cannot be installed after as the crankshaftis in place.Clean oil passages and make sure they are notclogged.Clean all metal components in a solvent.Engine block mating surfaces are best cleaned usinga combination of the chisel gasket remover(P/N 413 708 500) and a brass brush. Brush a firstpass in one direction then make the final brushingperpendicularly (90°) to the first pass (cross hatch).CAUTION: Do not wipe with rags. Use a newclean hand towel only.IMPORTANT: When beginning the application ofthe crankcase sealant, the assembly and the firsttorquing should be done within 10 minutes. It issuggested to have all you need on hand to savetime.1. Upper engine block half2. Oil bore in engine block3. Oil bore in bushing04-09-14 LMR2004_014_04_09A.FM

Section 04Subsection 09ENGINE (4-TEC)(ENGINE BLOCK)NOTE: It is recommended to apply this specificsealant as described here to get an uniform applicationwithout lumps. If you do not use the rollermethod, you may use your finger to uniformly distributethe sealant (unlike the Dreibond sealingcompound, using a finger will not affect the adhesion).Use the silicone-based Loctite 5910 (P/N 293 800081) on mating surfaces.CAUTION: Do not use Loctite 515 or 518 to sealcrankcase. Do not use Loctite Primer N with theLoctite 5910. Using these products or non siliconebasedsealant over a previously sealed crankcasewith Loctite 5910 will lead to poor adhesion andpossibly a leaking crankcase. These products arechemically incompatible. Even after cleaning, theLoctite 5910 would leave incompatible microscopicparticles.Use a plexiglas plate and apply some sealant on it.Use a soft rubber roller (50 - 75 mm (2 - 3 in))(available in arts products suppliers for printmaking)and roll the sealant to get a thin uniform coaton the plate (spread as necessary). When ready,apply the sealant on crankcase mating surfaces.6 16 15 14 4 9 2 10 11 12 13 85 23 22 3 21 17 18 1 19 20 7R1503motr06BApply Loctite 243 (blue) on threads. Torque engineblock screws no. 3 at first to 40 N•m (30 lbf•ft)and in a second sequence to 55 N•m (41 lbf•ft).Torque engine block screws no. 7 to 22 N•m(16 lbf•ft).Before continuing the installation process, the axialclearance of balance shaft and crankshaft mustbe checked.1F12R17ADo not apply in excess as it will spread out insidecrankcase.NOTE: Do not use Loctite Primer N with this sealant.The sealant curing time is similar to the Loctite518 without using the Primer N, which is 4 to24 hours.Tighten engine block screws according to followingsequence.R1503motr41A 21. Dial gauge2. CrankshaftCRANKSHAFT AXIAL CLEARANCE mm (in)NEW MINIMUMNEW MAXIMUMSERVICE LIMIT0.08 mm (.003 in)0.22 mm (.009 in)0.35 mm (.014 in)LMR2004_014_04_09A.FM 04-09-15

Section 04 ENGINE (4-TEC)Subsection 09 (ENGINE BLOCK)11R1503motr42A 21. Dial gauge2. Balance shaftBALANCE SHAFT AXIAL CLEARANCE mm (in)NEW MINIMUMNEW MAXIMUMSERVICE LIMITInstall the crankshaft cover before mounting theengine bracket. Put some oil on O-ring and pressthe cover in. The crankshaft cover must be evenwith the engine block surface.10.02 mm (.001 in)0.25 mm (.010 in)0.35 mm (.014 in)R1503motr18A1. Crankshaft locking toolInstall cylinder head, PTO housing and the otherparts in accordance with the proper installationprocedures.PISTON/CONNECTING RODRemovalDisassemble engine block according to ENGINEBLOCK REMOVAL above.Remove connecting rod screws.1R1503motr08AR1503motr19A 21. O-ring2. Crankshaft coverCAUTION: Install crankshaft locking tool (P/N 529035 821) right away to put crankshaft in TDC positionbefore installing the camshaft and rockers(refer to CYLINDER AND HEAD).1. Connecting rod screwsNOTE: Before removing the connecting rod bearingcaps, mark them to remember the right positionwhen reassembling.Pull piston with connecting rod out of the cylinders.04-09-16 LMR2004_014_04_09A.FM

Section 04Subsection 09ENGINE (4-TEC)(ENGINE BLOCK)Remove one piston circlip no. 8 and discard it.R610motr134A1211. Piston circlipNOTE: The removal of both piston circlips is notnecessary to remove piston pin.Push piston pin no. 9 out of piston.123R610motr73A1. Bore gauge2. Connecting rodR610motr137AAR1503motr27A1. Piston2. Piston pin3. CirclipDetach piston no. 10 from connecting rod.InspectionConnecting Rod/Piston Pin ClearanceMeasure piston pin. Compare to inside diameterof connecting rod no. 23.A. Piston pin diameter in the area of the bushingCONNECTING ROD SMALL END DIAMETERmm (in)NEW MINIMUMNEW MAXIMUMSERVICE LIMITNEW MINIMUMNEW MAXIMUMSERVICE LIMITPISTON PIN DIAMETERmm (in)23.01 mm (.9059 in)23.02 mm (.9063 in)23.07 mm (.908 in)22.996 mm (.9053 in)23.000 mm (.9055 in)22.990 mm (.9051 in)LMR2004_014_04_09A.FM 04-09-17

Section 04 ENGINE (4-TEC)Subsection 09 (ENGINE BLOCK)PISTON PIN BORE CLEARANCEmm (in)SERVICE LIMIT 0.080 mm (.0035 in)If the connecting rod small end diameter is out ofspecification, replace connecting rod.Connecting Rod Big End Radial PlayMeasure inside diameter of connecting rod bigend. Compare to crankpin.To measure the connecting rod big end diameter,use the OLD screws no. 11.Install the OLD bushings no. 12 as they weremounted initially.Do the torque procedure as described below.PistonInspect piston for scoring, cracking or other damages.Replace piston and piston rings if necessary.Using a micrometer, measure piston at 18 mm(.709 in) perpendicularly (90°) to piston pin axis.AR610motr136A11. Measuring perpendicularly (90°) to piston pin axisA. 18 mm (.709 in)The measured dimension should be as describedin the subsequent table. If not, replace piston.ANEW NOMINALPISTON MEASUREMENTmm (in)99.951 to 99.969 mm(3.935 to 3.936 in)SERVICE LIMIT99.80 mm (3.929 in)R610motr76AA. Connecting rod big end bushingCONNECTING ROD BIG END DIAMETERmm (in)SERVICE LIMIT 45.080 mm (1.774 in)Piston/Cylinder ClearanceAdjust and lock a micrometer to the piston dimension.1CONNECTING ROD BIG END CLEARANCEmm (in)SERVICE LIMIT 0.09 mm (.0035 in)Use NEW bushings no. 12, when connecting rodbig end diameter is out of specification.F00B08A1. Micrometer set to the piston dimension04-09-18 LMR2004_014_04_09A.FM

Section 04Subsection 09ENGINE (4-TEC)(ENGINE BLOCK)With the micrometer set to the dimension, adjusta cylinder bore gauge to the micrometer dimensionand set the indicator to 0 (zero).F00B09A21. Use the micrometer to set the cylinder bore gauge2. Dial bore gauge1If clearance exceeds specified tolerance, rehonecylinder sleeve and replace piston ass’y by oversize.NOTE: It is not necessary to have all pistons replacedwith an oversize if they are not all out of specification.Mixed standard size and oversize pistonare allowed.NOTE: Make sure the cylinder bore gauge indicatoris set exactly at the same position as with themicrometer, otherwise the reading will be false.Piston PinUsing synthetic abrasive woven, clean depositsfrom piston pin.Inspect piston pin for scoring, cracking or otherdamages.Measure piston pin. See the following illustrationfor the proper measurement positions.Piston Pin/Connecting Rod Bushing ClearanceMeasure inside diameter of connecting rod.CONNECTING ROD SMALL END DIAMETERmm (in)NEW MINIMUMNEW MAXIMUMSERVICE LIMIT23.01 mm (.9059 in)23.02 mm (.9063 in)23.07 mm (.908 in)1F00B0AATYPICAL1. Indicator set to 0 (zero)Position the dial bore gauge 62 mm (2.44 in)above cylinder base, measuring perpendicularly(90°) to piston pin axis.Read the measurement on the cylinder bore gauge.The result is the exact piston/cylinder wall clearance.PISTON/CYLINDER CLEARANCE mm (in)21NEW NOMINALSERVICE LIMIT0.024 to 0.056 mm(.0009 to .0022 in)0.090 mm (.004 in)R610motr73ANOTE: Make sure used piston is not worn. See PIS-TON MEASUREMENT above.1. Bore gauge2. Connecting rodLMR2004_014_04_09A.FM 04-09-19

Section 04 ENGINE (4-TEC)Subsection 09 (ENGINE BLOCK)Replace connecting rod if diameter of connectingrod small end is out of specifications. Refer toCRANKSHAFT AND BALANCER SHAFT for removalprocedure of connecting rod.InstallationFor installation, reverse the removal procedure.Pay attention to the following details.Apply engine oil on the piston pin.Insert piston pin into piston and connecting rod.Use the piston circlip installer (P/N 529 035 765)to assemble the piston circlip.CAUTION: Secure piston pin with new pistoncirclips.NOTE: Take care that the hook of the piston circlipis positioned properly.12Using a piston ring compressor plier, such Snap-On RC-980, slide piston into cylinder.R1503motr29ACAUTION: Take care that piston will be installedwith the punched arrow on piston top to the exhaustside.1R1503motr28A1. Sleeve with piston circlip inside2. Assembly jig from piston clip installerR1503motr30A1. Arrow should indicate to the exhaust sideR610motr134BCORRECT POSITION OF THE PISTON CIRCLIP04-09-20 LMR2004_014_04_09A.FM

Section 04Subsection 09ENGINE (4-TEC)(ENGINE BLOCK)Put bushings correctly in place and clean the splitsurface on both sides (cracked area) carefully.31 2PISTON RINGSRemovalRemove piston assembly as described above.Remove rings.InspectionRing/Piston Groove ClearanceUsing a feeler gauge measure each ring/pistongroove clearance. If the clearance is too large, thepiston and the piston rings should be replaced.RING/PISTON GROOVE CLEARANCEmm (in)NEW MINIMUMR610motr79AUPPERCOMPRESSION RING0.025 mm (.001 in)1. Half bushing of connecting rod big end2. Split surface of the connecting rod3. Protrusion of bushing in line with connecting rod grooveTorque NEW connecting rod screws no. 11 as perfollowing procedure:– Install screws and torque to 45 N•m (33 lbf•ft).Do not apply any thread locker product.– Finish tightening the screws with an additional90° turn using an angle torque wrench.CAUTION: Failure to strictly follow this proceduremay cause screw to loosen and lead to enginedamage. Besides, as the screws have beenstretched from the previous installation, it isvery important to use new screws at assembly.LOWERCOMPRESSION RINGOIL SCRAPER RINGUPPERCOMPRESSION RINGLOWERCOMPRESSION RINGOIL SCRAPER RINGALLNEW MAXIMUMSERVICE LIMIT0.015 mm (.0006 in)0.020 mm (.0008 in)0.070 mm (.0028 in)0.060 mm (.0024 in)0.055 mm (.0021 in)0.15 mm (.006 in)12R1503motr31A1. Angle torque wrenchR1503motr32A 11. Piston2. Filler gaugeLMR2004_014_04_09A.FM 04-09-21

Section 04 ENGINE (4-TEC)Subsection 09 (ENGINE BLOCK)Ring End GapUPPERCOMPRESSION RINGLOWERCOMPRESSION RINGOIL SCRAPER RINGRING END GAPmm (in)NEW MINIMUMNEW MAXIMUM0.15 mm (.006 in)0.15 mm (.006 in)0.15 mm (.006 in)CAUTION: Ensure that upper and lower ringsare not interchanged.NOTE: Use a ring expander to prevent breakageduring installation. The oil ring must be installed byhand.Check that rings rotate smoothly after installation.Space the piston ring end gaps 120° apart and donot align the gaps with the piston pin bore or thethrust side axis.AAAUPPERCOMPRESSION RINGLOWERCOMPRESSION RINGOIL SCRAPER RING0.35 mm (.014 in)0.35 mm (.014 in)0.30 mm (.012 in)1ALLSERVICE LIMIT1 mm (.04 in)2Measure position for ring end gap in the area of 8to 16 mm (.315 to .630 in) from top of cylinder.NOTE: In order to correctly position the ring in thecylinder, use piston as a pusher.Using a feeler gauge, check ring end gap. Replacering if gap exceeds above described specified tolerance.A31C2OA1. DO NOT align ring gap with piston trust side axis2. DO NOT align ring gap with piston pin bore axisA. 120°InstallationFor installation, reverse the removal procedure.Pay attention to the following details.Install the oil scraper ring first, then the lower compressionring with the word “TO” facing up, thenthe upper ring with the word “T” facing up.123A31C2NA1. Upper compression ring2. Lower compression ring3. Oil scraper ring04-09-22 LMR2004_014_04_09A.FM

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 01 (TABLE OF CONTENTS)TABLE OF CONTENTS 0OVERVIEW............................................................................................................................. 05-02-1COMPLETE ELECTRICAL SYSTEM OVERVIEW.............................................................. 05-02-2MAGNETO SYSTEM AND POWER SUPPLY ................................................................... 05-02-3OPERATING PRINCIPLE OF ENGINE MANAGEMENT ................................................... 05-02-3AIR INDUCTION................................................................................................................. 05-02-3FUEL DELIVERY SYSTEM................................................................................................. 05-02-3BASIC OPERATION ........................................................................................................... 05-02-3INTAKE MANIFOLD........................................................................................................... 05-02-4FUEL PUMP MODULE....................................................................................................... 05-02-4ELECTRONIC MANAGEMENT.......................................................................................... 05-02-5ECM (ENGINE CONTROL MODULE)................................................................................ 05-02-5ECM — GENERAL FUNCTIONS ....................................................................................... 05-02-6EMS — ENGINE MANAGEMENT FUNCTIONS............................................................... 05-02-8VCM — VEHICLE CONTROL MODULE ............................................................................ 05-02-10COMPONENT INSPECTION AND ADJUSTMENT .............................................................. 05-03-1GENERAL ........................................................................................................................... 05-03-1FUEL SYSTEM ................................................................................................................... 05-03-1ELECTRICAL SYSTEM....................................................................................................... 05-03-2ENGINE CONNECTOR PIN-OUT ...................................................................................... 05-03-3CONNECTORS ON ENGINE ............................................................................................. 05-03-4AIR INDUCTION SYSTEM................................................................................................. 05-03-5THROTTLE BODY .............................................................................................................. 05-03-5FUEL DELIVERY................................................................................................................. 05-03-8FUEL PUMP ....................................................................................................................... 05-03-9FUEL SYSTEM PRESSURIZATION ................................................................................... 05-03-10FUEL RAIL .......................................................................................................................... 05-03-12FUEL INJECTOR ................................................................................................................ 05-03-12ELECTRONIC MANAGEMENT.......................................................................................... 05-03-14ECM ECU AND VCM REPLACEMENT.............................................................................. 05-03-14ENGINE WIRING HARNESS ............................................................................................. 05-03-15THROTTLE POSITION SENSOR (TPS) ............................................................................. 05-03-17IDLE BYPASS VALVE ........................................................................................................ 05-03-19CRANKSHAFT POSITION SENSOR (CPS) ....................................................................... 05-03-19CAMSHAFT POSITION SENSOR (CAPS) ......................................................................... 05-03-21MANIFOLD AIR TEMPERATURE SENSOR (MATS)......................................................... 05-03-22COOLANT TEMPERATURE SENSOR (CTS)..................................................................... 05-03-23MANIFOLD AIR PRESSURE SENSOR (MAPS)................................................................ 05-03-23EXHAUST GAS TEMPERATURE SENSOR (EGT)............................................................ 05-03-24KNOCK SENSOR (KS) ....................................................................................................... 05-03-24LMR2004-030_05_01ATOC.FM 05-01-1

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 01 (TABLE OF CONTENTS)OIL PRESSURE SWITCH (OPS) ......................................................................................... 05-03-25OIL SEPARATOR PRESSURE SWITCH (OSPS)................................................................ 05-03-26TOPS VALVE (blow-by) ...................................................................................................... 05-03-28IGNITION COILS................................................................................................................. 05-03-29TDC SETTING (Top Dead Center) ..................................................................................... 05-03-31ENGINE START/STOP SWITCH VERIFICATION............................................................... 05-03-31SAFETY LANYARD SWITCH VERIFICATION.................................................................... 05-03-31SPARK PLUGS.................................................................................................................... 05-03-31CRANKING SYSTEM.......................................................................................................... 05-03-32DIAGNOSTIC PROCEDURES................................................................................................. 05-04-1GENERAL............................................................................................................................ 05-04-1SELF-DIAGNOSTIC MODE ................................................................................................ 05-04-2VCK (Vehicle Communication Kit) ................................................................................... 05-04-34-TEC SYSTEM FAULT CODES......................................................................................... 05-04-305-01-2 LMR2004-030_05_01ATOC.FM

Section 05ENGINE MANAGEMENT (4-TEC)Subsection 02 (OVERVIEW)OVERVIEW 0ENGINE CONTROL MODULE — OVERVIEWROTAX 4-TEC 1503Cyl. 1 Cyl. 2 Cyl. 3MAGNETOCon. BCon. AKSMAPSCPSMATSOPSTPSCTSCAPSINJECTOR 1, 2, 3ECMECUIDLE BYPASS VALVETOPS SWITCHTOPS VALVEOSPSIGNITION COIL 1, 2, 3EGTMUFFLERR1503motr212SBATTERYREGULATOR/RECTIFIERENGINEFUSEBLOCKENGINE POWER SUPPLYECM ECU Engine Management SystemElectronic Control UnitKS Knock SensorCPS Cranshaft Position SensorOSPS Oil Separator Pressure SensorCTS Coolant Temperature SensorCAPS Camshaft Position SensorEGT Exhaust Gas TemperatureMAPS Manifold Air Pressure SensorMATS Manifold Air Temperature SensorTOPS Tip-Over Protection SystemCon. A Connector for Engine Wiring HarnessCon. B Connector for Boat Wiring HarnessLMR2004_015_05_02A.FM 05-02-1

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 02 (OVERVIEW)COMPLETE ELECTRICAL SYSTEM OVERVIEWCOMMUNICATIONLINK- TPS- MAPS- MATS- CTS- EGT- KS- OPS- OSPS- CPS- DESS- IDLEBYPASSVALVE- START/STOPSWITCH- STARTINGSOLENOID- FUEL PUMP- FUEL INJECTORS- IGNITION COILS- TOPS VALVE- TOPS SWITCH- CAPSECM ECUWH/BKWH/REENGINE FUSE BLOCKWH/BKWH/RECOMMUNICATION LINKWH/BKWH/REVCM- POWER TOECM ECU- ENGINEWARNINGS- TACHOMETER- SPEED SENSOR/SPEEDOMETER- FUEL LEVELSENDER- BEEPERVCK(COMMUNICATIONPORT)- BEEPER- ENGINEWARNINGS- TACHOMETER- DESS SWITCHECMF18L33SThese components are shared between the ENGINE FUSE BLOCK and theECM ECU. The ENGINE FUSE BLOCK supplies the power while the EMS ECUcontrols and completes the circuit by switching it to the ground.COLOUR CODEWH = WHITEBK = BLACKRE = REDNOTE: This procedure to be performed for eachengine.The complete electrical system is managed bymicro-controllers working together. Overall, theVCM (vehicle control module) manages the vehicleelectrical system, the ECM (engine control module)controls the engine.A communication link is used between the electronicmodules to communicate with each other.It consists of a twisted pair of wires (WHITE/REDand WHITE/ BLACK).For communication link troubleshooting, refer toINSTRUMENTS AND ACCESSORIES in ELECTRI-CAL section.The communication link is also used to communicateinformative messages, monitoring and diagnosticcodes to the VCK (vehicle communication kit)where B.U.D.S. (Bombardier Utility and DiagnosticSystem) is used for diagnosing and troubleshootingthe system.The fault codes can be seen from B.U.D.S. Refer toDIAGNOSTIC PROCEDURES section.05-02-2 LMR2004_015_05_02A.FM

Section 05ENGINE MANAGEMENT (4-TEC)Subsection 02 (OVERVIEW)MAGNETO SYSTEM ANDPOWER SUPPLYThe magneto is the primary source of electrical energy.It transforms magnetic field into electric current(AC).The magneto has a 3 phases, delta wound stator on18 poles. Capacity is 380 watts.It supplies DC current to battery after being transformedby the voltage regulator/rectifier. Refer toCHARGING SYSTEM.OPERATING PRINCIPLE OFENGINE MANAGEMENTA highly advanced engine control module (ECM)has been used to ensure a high power output withcleanest combustion. The ECM calculates theproper air/fuel mixture and ignition timing for eachcylinder separately. The fuel is injected into the intakeport of each cylinder.NOTE: On the 1503, PTO and magneto (MAG) areon the same engine side (rear). Each cylinder isreferenced as 1, 2 and 3 instead of PTO, CENTREand MAG. The numbers are stamped on the valvecover.NOTE: “ECM” stands for engine control module.“ECM” includes an ECU (electronic control unit),sensors, injectors, electromagnetic valves and ignitionsystem.AIR INDUCTIONAir for combustion is drawn directly at the front ofthe engine through one 52 mm throttle body. Theair flow is controlled by a throttle plate and an idlebypass valve respectively. The air continues throughthe intake manifold, which contains the flame arresterand goes into the cylinder head.212 3R1503motr216A152 mm THROTTLE BODY1. Idle bypass valve2. Throttle position sensor (TPS)R1503motr218A1. Cylinder 12. Cylinder 23. Cylinder 3FUEL DELIVERY SYSTEMBASIC OPERATIONWhen the intake valve reaches the correct position,the ECM ECU (Electronic Control Module)opens the fuel injector and fuel is discharged intothe intake port at the air intake manifold by thehigh fuel pressure inside the fuel rail. The air/fuelmixture enters then the combustion chamberthrough the open intake valve. This mixture is thenignited by the spark plug.LMR2004_015_05_02A.FM 05-02-3

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 02 (OVERVIEW)INTAKE MANIFOLD1325Throttle BodyIt is a 52 mm throttle body mounted on intake manifold.Fitted on the throttle body, there is the TPS andthe idle bypass valve which allows the ECM ECU tocontrol the RPM while the throttle plate is closed.FUEL PUMP MODULER1503motr214BINTAKE MANIFOLD1. Electronic Control Unit (ECM ECU)2. Fuel rail3. Injector4. Throttle body5. Ignition coil6. Manifold air pressure sensor (MAPS)7. Manifold air temperature sensor (MATS)The intake manifold is mounted on the engine blockon the engine starboard side. It provides support forthe fuel injectors, the fuel rail, the ECM ECU, theflame arrester and the throttle body. The air intakemanifold is a resonator between the throttle bodyand the air intake at the cylinder head with theflame arrester.Fuel RailThe fuel rail is a small tube on which the three injectorsare mounted. It ensures all the time, thatenough fuel at the right pressure can be deliveredto the fuel injectors. The fuel rail is fed by the fuelpump with a fuel pressure of approximately 303 kPa(44 PSI).Fuel InjectorThree fuel injectors (one per cylinder) are used toinject fuel into the intake port of the cylinder head.Flame Arrester6 7The flame arrester is a tube inside the air intakemanifold. It prevents flames leaving through theintake system if the engine backfires.4R1503motr217AThe fuel pump modules are located inside the fueltank. Each module includes fuel pump, fuel pressureregulator and fuel level sensor.Fuel PumpIt provides fuel pressure and flow rate to the system.Fuel Pressure RegulatorA fuel pressure regulator controls the pressure inthe system and allows the excess of fuel to returnto the fuel tank. The fuel pressure regulator regulatesthe fuel pressure at approximately 303 kPa(44 PSI).Fuel FilterA mesh filter is located at the bottom of the fuelpump module inside the fuel tank.05-02-4 LMR2004_015_05_02A.FM

Section 05ENGINE MANAGEMENT (4-TEC)Subsection 02 (OVERVIEW)ELECTRONIC MANAGEMENTECM (Engine Control Module)The engine control module is controlled by theECM ECU.1ENGINECONTROLMODULE(ECM)ECM FUNCTIONSFuel injectionsystemIgnition systemStarting systemData transferwith VCMDESS systemand learning keyRPM limiterR1503motr219ALimp home modeR1503motr215A1. ECM ECUECM ECUThe ECM ECU is mounted on the intake manifold.It controls all engine management functions, by processingthe information given by various sensors.1R1503motr214A1. ECM ECU on intake manifoldThe ECM ECU gets its power by the engine fuseblock which is directly powered by the battery. It isresponsible for the following engine management/electrical functions:– interpreting information– distributing information– start/stop function– timer– DESS (Digitally Encoded Security System)– ignition timing control– injection control– The ECM ECU applies the proper map (injectionand ignition) for optimum engine operation in allconditions.– engine RPM limiter– etc.The ECM ECU features a permanent memory thatwill keep the programmed safety lanyard(s) active,fault codes and other engine information, evenwhen the battery is removed from the sport boat.LMR2004_015_05_02A.FM 05-02-5

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 02 (OVERVIEW)ECM — GENERAL FUNCTIONSSafety Lanyard ReminderIf engine is not started within 5 seconds after installingthe safety lanyard on its post, 4 very shortbeeps every 3 second interval will sound for approximately5 minutes to remind you to start theengine or to remove safety lanyard. Afterwards, thebeeps will stop. The same will occur when safetylanyard is left on its post 5 seconds after engine isstopped.CAUTION: Leaving the safety lanyard on its postwhen engine is not running will slowly dischargebattery.Antistart FeatureThis system allows starting the vehicle only withsafety lanyard(s) that has been programmed to operatea specific sport boat. This functionality is theDESS system. See below for details.Digitally Encoded Security System(DESS)The following components are specially designedfor this system: Vehicle Control Module (VCM),ECM ECU, safety lanyard cap and safety lanyardpost.The safety lanyard cap contains a magnet and aROM chip. The magnet actually closes the reedswitch inside the post which is the equivalent of amechanical ON/OFF switch. The chip has a uniquedigital code.The DESS circuitry in the ECM ECU is activated atthe factory. Therefore, a safety lanyard must beprogrammed to start the engine.NOTE: Actually, it is the memory of the ECM ECUwhich is programmed to recognize the digital codeof the safety lanyard cap. This is achieved with theVCK (Vehicle Communication Kit) (P/N 529 035844). Refer to B.U.D.S. help system to programa safety lanyard.The system is quite flexible. Up to 8 safety lanyardsmay be programmed in the memory of thesport boat ECM. They can also be erased individually.NOTE: If desired, a safety lanyard can be used onother sport boats equipped with the DESS. Itonly needs to be programmed for that sport boat.When connecting a safety lanyard cap on the post,the DESS is activated and will emit audible signals:– 2 short beeps indicate a working safety lanyard.Engine starting can take place.– 1 long beep indicates a wrong safety lanyard isbeing used or that something is defective. Enginestarting is not allowed.The memory of the ECM ECU features a selfdiagnosticmode for the DESS operation. Refer toDIAGNOSTIC PROCEDURES section for more information.The memory of the ECM ECU is permanent. If thebattery is disconnected, no information is lost.When ordering a new ECM ECU from the regularparts channel, the DESS circuitry will be activated.Engine StartingIf the ECM ECU recognizes a valid safety lanyard,it allows engine to start when the start/stop switchis pressed.If start/stop button is held after engine has started,the ECM ECU automatically stops the starterwhen the engine speed reaches 1600 RPM.Engine RPM LimiterThe ECM ECU will limit the maximum engine speed.Engine StoppingThere are 2 ways to stop the engine.Press and hold start/stop switch or remove the safetylanyard cap from its post.If the engine is stopped by removing the safetylanyard, it is impossible to restart the engine asexplained in the engine starting section.If safety lanyard cap is reconnected within 15 seconds,the current supply to the engine managementis not cut and the safety lanyard will be validated.Low-Oil Pressure Warning DeviceWhen the oil pressure falls under a certain level,the ECM ECU sends out a signal for the beeperand to the warning gauge. Additionally the enginegoes into limp home mode.05-02-6 LMR2004_015_05_02A.FM

Section 05ENGINE MANAGEMENT (4-TEC)Subsection 02 (OVERVIEW)High Coolant Temperature and EGTWarning DeviceWhen the coolant temperature or the exhaust gastemperature is getting too high, the ECM ECU sendssignals to the beeper and the warning gauge. Additionnallythe engine goes into limp home mode.The engine fuse block distributes power from thebattery to all engine components and boat gauges.6 5 4Fuse BlockThe fuse block for each engine is mounted on thehull just underneath the port and starboard rearstorage compartments. Remove rear seat storagetubs to access fuse blocks.The ECM ECU switches the ground to completethe electrical circuits it controls. Take this intoaccount when troubleshooting the electrical system.Refer to the illustration at the beginning ofthis section.F04H79ATYPICAL1. Fuel pump2. Cylinder 33. ECM4. Cylinder 15. Cylinder 26. Gauges12 3F04H73A11. Port fuse blockF04H74A11. Starboard fuse blockLMR2004_015_05_02A.FM 05-02-7

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 02 (OVERVIEW)EMS — ENGINE MANAGEMENT FUNCTIONS1503 4-TEC CONTROL SYSTEMINPUTSOUTPUTSThrottle position (TPS)Crankshaft position (CPS)Camshaft position (CAPS)Coolant temperature (CTS)Manifold air pressure (MAPS)Manifold air temperature (MATS)Exhaust gas temperature (EGT)Oil pressure (OPS)Oil separator pressure (OSPS)Knock sensor (KS)Battery voltage (BV)ENGINE CONTROLMODULE(ECM)Fuel pumpStarter solenoidTOPS valveIgnition coil (3)Fuel injectorIdle bypass valveCommunicationport to VCMDigitally EncodedSecurity System (DESS)Start/Stop switchTip-over protection system (TOPS)R1503motr220S05-02-8 LMR2004_015_05_02A.FM

Section 05ENGINE MANAGEMENT (4-TEC)Subsection 02 (OVERVIEW)This engine management system controls boththe fuel injection and the ignition timing.As shown in the 1503 4-TEC CONTROL SYSTEMillustration, the ECM ECU is the central point ofthe fuel injection system. It reads the inputs,makes computations, uses pre-determined parametersand sends the proper signals to the outputsfor proper engine management.The ECM ECU also stores the fault codes and generalinformation such as: operating conditions, vehiclehours, serial numbers, customer and maintenanceinformation.Electronic Fuel InjectionThe ECM ECU reads the signals from differentsensors which indicate engine operating conditionsat milli-second intervals.Signals from sensors are used by the ECM ECUto determine the injection parameters (fuel maps)required for optimum air-fuel ratio.The CPS, the MATS, the MAPS and the TPS arethe primary sensors used to control the injectionand ignition timing. Other sensors (like temperaturesensors, etc.) are used for secondary input.NOTE: The EGT, OPS and OSPS sensors do notprovide control inputs to the ECM ECU. Their solepurpose is to protect the engine components byemitting a warning signal and/or a fault code in theevent of overheating or low oil pressure or TOPSvalve fault.Ignition SystemThe ignition system is a digital inductive type. TheECM ECU controls the ignition system parameters,such as spark timing, duration and firing inorder to achieve the proper engine requirements.Ignition CoilsThree separate ignition coils induce voltage to ahigh level in the secondary windings to produce aspark at the spark plug.The ignition coils receive input from the ECM ECU.Each coil provides high voltage to its correspondingspark plug.This ignition system allows spark plugs to sparkindependently.NOTE: Ignition coil cables are not interchangeabledue to different lengths.All three ignition coils are located on the cylinderhead directly on the spark plugs.R1503motr213A1. Ignition coilsIgnition TimingThe ECM ECU is programmed with data (it containsignition mappings) for optimum ignition timingunder all operating conditions. Using engineoperating conditions provided by the sensors, theECM ECU controls the ignition timing for optimumengine operation.There is no mechanical adjustmentto perform.Knock SensorA knock sensor is mounted on the engine blockbehind the air intake manifold. It detects specificvibrations that would be typically generated by enginedetonation. If detonation occurs, the knocksensor detects this and the ECM ECU retards theignition advance temporarily (it goes in a specificmode) until detonation stops. The ECM ECU is ableto evaluate the knocking cylinder and modifies theignition advance on just the one detonating.Engine Modes of OperationThe ECM ECU controls different operation modesof the engine to allow proper operation for all possibleconditions: Cranking, start-up, idle, warm up,part load, full load, engine speed limiter, drownedengine and limp home (see below).Fuel-Flooded Engine1If engine is fuel-flooded and does not start, thisspecial mode can be activated to prevent fuel injectionand ignition while cranking. Proceed as followsto activate it.LMR2004_015_05_02A.FM 05-02-9

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 02 (OVERVIEW)With safety lanyard on its post while engine isstopped, press and HOLD throttle lever in neutralposition.Press the start/stop button. The mode is now on.Releasing throttle lever will bring back to its normalmode.If engine does not start, it may be necessary toremove spark plugs and crank engine with ragsover spark plug holes. Refer to COMPONENT IN-SPECTION AND ADJUSTMENT subsection. WARNINGWhen disconnecting coil from spark plug, alwaysdisconnect coil from main harness first.Never check for engine ignition spark from anopen coil and/or spark plug in the engine compartmentas spark may cause fuel vapor to ignite.Diagnostic ModeThe malfunctions are recorded in the memory ofthe ECM ECU. The memory of the ECM ECU canbe checked using the VCK (Vehicle CommunicationKit) (P/N 529 035 844) to see the fault codes. TheECM ECU and the VCK are able to communicatethrough a connector on the vehicle. Refer to theDIAGNOSTIC PROCEDURES section. B.U.D.S.Version 1.1 and up must be used for this system.VCM — VEHICLE CONTROLMODULEPower DistributionThe VCM distributes power from battery to all accessories.Accessories are protected by fuses integratedin the VCM. Fuse ratings are identifiedbeside their holder.If engine is water-flooded, refer to WATER FLOOD-ED ENGINE in MAINTENANCE section.Limp Home ModesBesides the signals seen above, the ECM ECUmay automatically set default parameters to theengine management to ensure the adequate operationof the sport boat if a component of the fuelinjection system is not operating properly.The following components failure will trigger a limphome mode: CTS, EGT, OPS, OSPS and TOPS.When minor faults occur, the fault and message/beeper will stop automatically, once the conditionno longer exists.Idling throttle and letting the engine return to idlespeed may allow normal operation to return. If thisdoes not work, try removing and reinstalling thesafety lanyard on its post.Depending on the malfunction, the sport boat speedmay be reduced and not allowed to reach its usualtop speed. The engine speed will be limited to 2500or 5000 RPM.These performance-reduced modes allow the operatorto go back home which would not be possiblewithout this advanced system. Refer to the DI-AGNOSTIC PROCEDURES for a complete chart.If a fault occurs and involves a limp home modeoperation, the engine management system will reduceengine RPM gradually to the proper level.F04H70A1. Courtesy lights2. Navigation lights3. Bilge pump4. Blower5. Radio6. AccessoriesIMPORTANT: Some components are continuouslypowered with the supply from the battery throughVCM.12345605-02-10 LMR2004_015_05_02A.FM

Section 05ENGINE MANAGEMENT (4-TEC)Subsection 02 (OVERVIEW)Gauges Current SupplyThe purpose of this function is to allow reading ofgauges without the engine running.Gauges are supplied with current whenever thesafety lanyard cap is installed on its post.NOTE: The fuel pump will be activated for 2 secondsto build up pressure in the fuel injection system,only when connecting the safety lanyard capto the post.Monitoring SystemThe ECM ECU monitors the electronic componentsof the fuel injection system and also the enginecomponents of the electrical system. When a faultoccurs, it sends audible signals through a beeper toinform you of a particular condition. Refer to theDIAGNOSTIC PROCEDURES section for the beepercoded signals chart.LMR2004_015_05_02A.FM 05-02-11

Subsection 03Section 05 ENGINE MANAGEMENT (4-TEC)(COMPONENT INSPECTION AND ADJUSTMENT)COMPONENT INSPECTION ANDADJUSTMENT 0NOTE: This procedure to be performed for eachengine.GENERALEngine problems are not necessarily related to theelectronic fuel injection system.It is important to ensure that the mechanical integrityof the engine/propulsion system is present:– good jet pump/drive system operation– good engine compression and properly operatingmechanical components, no leaks etc.– fuel pump connection and fuel lines withoutleaks.Check the chart in TROUBLESHOOTING sectionto have an overview of problems and suggestedsolutions.When replacing a component, always check itsoperation after installation.Whenever sport boat is out of water and engine isrunning, ensure to supply water through the connectoron jet pump support to cool down exhaustsystem.CAUTION: Never run engines without supplyingwater to the exhaust cooling systems whensport boat is out of water.FUEL SYSTEM WARNINGThe fuel system of a fuel injection systemholds much more pressure than on a carburetedsport boat. Prior to disconnecting a hoseor to removing a component from the fuelsystem, follow the recommendation describedhere. Some hoses may have morethan one clamp at their ends. Ensure to reinstallthe same quantity of clamps at assembly.– Use the VCK (Vehicle Communication Kit) (P/N529 035 844) to release the fuel pressure in thesystem. Look in the Activation section ofB.U.D.S. WARNINGFuel lines remain under pressure at all times.Always proceed with care and use appropriatesafety equipment when working on pressurizedfuel system. Wear safety glasses and workin a well ventilated area. Do not allow fuel tospill on hot engine parts and/or on electricalconnectors. Proceed with care when removing/installing high pressure test equipment or disconnectingfuel line connections. Use the VCK(Vehicle Communication Kit) to release fuelpressure prior to removing a hose. Cover thefuel line connection with an absorbent shoprag. Slowly disconnect the fuel hose to minimizespilling. Wipe off any fuel spillage in thebilge. Fuel is flammable and explosive undercertain conditions. Always work in a well ventilatedarea. Always disconnect battery prior toworking on the fuel system. After performing apressure test, use the valve on the fuel pressuregauge to release the pressure (if soequipped).– Always disconnect battery properly prior toworking on the fuel system. Refer to BATTERYsection.When the job is done, ensure that hoses from fuelrail going to fuel pump are properly secured in theirsupports. Then, pressurize the fuel system. Performthe high pressure test as explained in thissection and pressurize the fuel tank and fuel linesas explained in FUEL SYSTEM section.Properly reconnect the battery. WARNINGVerify fuel line connections for damage andthat NO fuel line is disconnected prior to installingthe safety lanyard on the DESS post. Alwaysperform the high pressure test if anycomponent has been removed. A pressure testmust be done before connecting the safety lanyard.The fuel pump is started each time thesafety lanyard is installed and it builds pressurevery quickly.LMR2004-016_05_03A.FM 05-03-1

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)To check fuel rail for leaks, first pressurize the systemthen spray soapy water on all hose connections,regulators and injectors. Air bubbles willshow the leaking area. Check also for fuel leaks orodors. WARNINGNever use a hose pincher on high pressurehoses.ELECTRICAL SYSTEMIt is important to check that the electrical systemis functioning properly:– battery– fuses– DESS– ignition (spark)– ground connections– wiring connectors.It is possible that a component seems to operatein static condition but in fact, it is defective. In thiscase, the best way to solve this problem is to removethe original part and replace it with onewhich is in good condition.Never use a battery charger to substitute temporarilythe battery, as it may cause the VCM/ECMECU to work erratically or not to work at all. Checkrelated-circuit fuse solidity and condition with anohmmeter. Visual inspection could lead to false results. WARNINGAll electrical actuators (idle bypass valve,TOPS valve, injectors, fuel pump, ignitioncoils and starter solenoid) are permanentlysupplied by the battery when the safety lanyardis installed. Always disconnect the batteryprior to disconnecting any electric or electronicparts.To perform verifications, a good quality multimetersuch as Fluke 111 (P/N 529 035 868) should be used.Pay particular attention to ensure that pins are notout of their connectors or bent. The troubleshootingprocedures cover problems not resulting fromone of these causes. WARNINGEnsure all terminals are properly crimped onwires and connector housings are properlyfastened.Before replacing an VCM or ECM ECU, alwayscheck electrical connections. Make sure that theyare very tight and they make good contact and thatthey are corrosion-free. Particularly check VCM andECM ECU ground connections. Ensure that contactsare good and clean. A “defective module”could possibly be repaired simply by unpluggingand replugging the VCM or ECM ECU. The voltageand current might be too weak to go through dirtywire pins. Check carefully if pins show signs ofmoisture, corrosion or if they look dull. Clean pinsproperly and then coat them prior to assembling asfollows:ECM ECU connectors, OPS and OSPS connectors:Apply a thin coat of DEOXIT contact lubricant(P/N 293 550 034).Other connectors: Apply a silicon-based dielectricgrease or other appropriate lubricant. If the newlyreplaced VCM or ECM ECU is working, try the oldone and recheck if it works.Ensure that all electronic components are genuine— any modification on the wiring harness maygenerate fault codes or bad operation.NOTE: For diagnostics purposes, use VehicleCommunication Kit (VCK). See DIAGNOSTIC PRO-CEDURES subsection.After a problem has been solved, ensure to clearthe fault(s) in the ECM ECU using the VCK. Referto DIAGNOSTIC PROCEDURES subsection.05-03-2 LMR2004-016_05_03A.FM

Subsection 03Section 05 ENGINE MANAGEMENT (4-TEC)(COMPONENT INSPECTION AND ADJUSTMENT)Resistance MeasurementWhen measuring the resistance with an ohmmeter,all values are given for a temperature of 20°C(69°F). The resistance value of a resistance varieswith the temperature. The resistance value forusual resistor or windings (such as injectors) increasesas the temperature increases. However,our temperature sensors are NTC types (NegativeTemperature Coefficient) and work the oppositewhich means that the resistance value decreasesas the temperature increases. Take it into accountwhen measuring at temperatures different from20°C (68°F). Use this table for resistance variationrelative to temperature for temperature sensors.TEMPERATURE RESISTANCE (ohms)°C °F NOMINAL LOW HIGH- 30 - 22 12600 11800 13400- 20 - 4 11400 11000 11800- 10 14 9500 8000 110000 32 5900 4900 690010 50 3800 3100 450020 69 2500 2200 280030 86 1700 1500 190040 104 1200 1080 132050 122 840 750 93060 140 630 510 75070 158 440 370 51080 176 325 280 37090 194 245 210 280100 212 195 160 210110 230 145 125 160120 248 115 100 125CONVERSION CHART FOR TEMPERATURE SENSORSThe resistance value of a temperature sensor maytest good at a certain temperature but it might bedefective at other temperatures. If in doubt, try anew sensor.Also remember this validates the operation of thesensor at ambient temperature. It does not validatethe over temperature functionality. To test it,the sensor could be removed from the engine/muffler and heated with a heat gun while it is stillconnected to the harness to see if the ECM ECUwill detect the high temperature condition and generatea fault code.NOTE: In case of overheating, EGT and CTS do notgenerate codes. The beeper will be activated andthe ECM will be set in limp home mode.ENGINE CONNECTOR PIN-OUTConnector PositionR1503motr166A 121. ECM ECU connector A2. Engine connectorECM ECU ConnectorUse this diagram to locate the pin numbers on theECM ECU connector A of the wiring harness whenperforming tests.1328R1503motr176AECM ECU CONNECTOR PIN-OUT (WIRING HARNESS SIDE)CAUTION: Probe on top of terminal only. Do nottry to probe inside terminal or to use a paperclip to probe inside terminal, it can damage thesquare-shaped terminal.CAUTION: Do not disconnect the ECM ECU connectorneedlessly. They are not designed to bedisconnected/reconnected repeatedly.11441 29LMR2004-016_05_03A.FM 05-03-3

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)Engine ConnectorUse this diagram to locate the pin numbers on theEngine connector of the wiring harness when performingtests.32142 3R1503motr192AENGINE CONNECTOR PIN-OUT (WIRING HARNESS SIDE)CONNECTORS ON ENGINERemovalTo remove connectors from engine connectorbracket, slide a flat screwdriver between the connectorbracket and the connectors and removeconnectors.F18Z0KA1. Engine connector bracket2. Deutsch connector3. Flat screwdriverTo disconnect two connectors slide a flat screwdriverbetween each other to disengage, press therelease button and disconnect them.112F18Z0JA1. Engine connector bracket2. Connectors1F18Z0LA 21. Flat screwdriver2. Connectors05-03-4 LMR2004-016_05_03A.FM

Subsection 03Section 05 ENGINE MANAGEMENT (4-TEC)(COMPONENT INSPECTION AND ADJUSTMENT)2AIR INDUCTION SYSTEMTHROTTLE BODY654F18Z0MA 1 21. Release button2. ConnectorsF18Z0NA 2 11. Connectors2. Press release button2R1503motr160A1. Throttle body2. Throttle cable attachment3. Throttle plate4. TPS5. Idle bypass channel6. Idle bypass valveMechanical Inspection1Check that the throttle plate moves freely andsmoothly while moving the throttle lever. Takethis opportunity to lubricate the throttle cable.IMPORTANT: The throttle body is designed to betamper proof. Changing the idle stop or modifyingit in any way will not increase performance orchange the idle speed but may cause poor startabilityand erratic idling.Before replacing any part, check the following asthese could be causing the fault. Perform the testwhile the engine is not running.– Throttle cable adjustment too tight. Not returningfully to idle stop.– Throttle body idle set screw is loose or worn.– TPS is loose.– Idle bypass valve is loose.– Corroded or damaged wiring or connectors.– Throttle body has been replaced and the closedthrottle and idle actuator reset has not been performed.– ECM ECU has been replaced and the closedthrottle and idle actuator reset has not been performed.3LMR2004-016_05_03A.FM 05-03-5

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)Electrical InspectionRefer to THROTTLE POSITION SENSOR (TPS) andIDLE BYPASS VALVE in ELECTRONIC MANAGE-MENT below.Adjustment1ReplacementRemovalTo remove the throttle body from engine, proceedas follows:– Disconnect air intake silencer hose from throttlebody.– Remove retaining screws of throttle body.R1503motr161A2R1503motr205A 121. Throttle body2. Screws– Slightly pull throttle body out.– Disconnect connectors from idle bypass valve,and TPS.– Disconnect throttle cable.InstallationInstallation of the new throttle body is the reverseof the removal procedure.For TPS and idle bypass valve replacement procedures,refer to the respective paragraph in ELEC-TRONIC MANAGEMENT below.THROTTLE BODY1. Idle stop screwCAUTION: Do not make any changes to the idlestop screw.The adjustment of the idle stop screw is optimizedby the throttle body manufacturer and locked toprevent any modification.CAUTION: Never attempt to adjust the idlespeed through the throttle body tamper proofscrew. If so, it would impair the idle speed stability.Besides, no adjustment could be performedby the dealer nor the factory to correct the idlespeed. The throttle body would need to be replaced.Also take into account that this mightchange the engine emission level and the enginemight not meet the EPA/CARB requirements.CAUTION: Do not alter or tamper with throttlecable adjustment or routing. It may cause poorstartability and erratic idling.The only thing that has to be performed when thethrottle body has been replaced is the closed throttleand idle actuator reset. Refer to THROTTLE PO-SITION SENSOR (TPS) in ELECTRONIC MANAGE-MENT below.05-03-6 LMR2004-016_05_03A.FM

Subsection 03Section 05 ENGINE MANAGEMENT (4-TEC)(COMPONENT INSPECTION AND ADJUSTMENT)Throttle Cable AdjustmentMechanically adjust the throttle cable.Lubricate cable with BOMBARDIER LUBE lubricant.When throttle lever is at the idle position, the cablemust have a free play of 0.5 - 4.0 mm (1/64 - 5/32 in).Ensure throttle body is fully open at full throttleposition. At this position, throttle lever stopper isalmost in contact with throttle body.NOTE: Apply a light pressure on the throttle plate,a slight play should be obtained.CAUTION: If there is no free-play at idle position,it may cause poor idling and startability.Improper cable adjustment will cause strain oncable and/or damage cable bracket or throttlelever.To adjust, loosen jam nut then turn adjustment nutas necessary.F18F07A 3 211. Adjustment nut2. Jam nut3. Throttle lever stopperTighten jam nut and recheck adjustment. WARNINGMake sure idle speed stopper contacts throttlecam when throttle lever is fully to the rear.Closed Throttle and Idle Actuator ResetPerform the closed throttle and idle actuator resetas described in THROTTLE POSITION SENSOR(TPS) in ELECTRONIC MANAGEMENT below.LMR2004-016_05_03A.FM 05-03-7

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)FUEL DELIVERY4-TEC FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW CHARTFuel pump does not runCheck fuses.Check safety lanyard connection.Check fuel pump operation.Repair or replace if necessary.Connect safety lanyardInstall fuel pressure gaugeon fuel pressure lineConnect safety lanyardFuel pump runsfor 2 sec. then stopsReplace fuelpump moduleFuel pump runsRepair orreplaceFuel pressure lessthan 303 kPa (44 PSI)Fuel pressure is303 kPa (44 PSI)Fuel pressure morethan 303 kPa (44 PSI)FailsCheck fuel line/rail for leaksFailsOKPerform fuel pump testCrank or startengineOKFastpressure dropFuel pressure lessthan 303 kPa (44 PSI)Fuel pressure morethan 303 kPa (44 PSI)Fuel pressure is303 kPa (44 PSI)NoYesVerify fuelpump checkvalveOKCheckfuel line/rail for leaksFailsRepair orreplaceFUEL SYSTEM OKFailsOKFailsCheck fuelinjectorOKPerform fuelpump testReplace fuelpump moduleRetestOKR1503motr209S05-03-8 LMR2004-016_05_03A.FM

Subsection 03Section 05 ENGINE MANAGEMENT (4-TEC)(COMPONENT INSPECTION AND ADJUSTMENT)FUEL PUMPNOTE: This procedure to be performed for eachengine.Before proceeding to the pressure test ensure thebattery is fully charged. Battery voltage must beover 12 volts.Release the fuel pressure in the system usingB.U.D.S. Look in the Activation tab. WARNINGThe fuel hose may be under pressure. Coverthe fuel line connection with an absorbentshop rag. Slowly disconnect the fuel hose torelease the pressure. Wipe off any fuel spillageinside bilge.The pressure test will show the available pressureat the fuel pump outlet. It validates the pressureregulator, the fuel pump and leaks in the system.Ensure there is no leak from hoses and fittings. Repairany leak.Ensure there is enough gas in fuel tank.To access fuel pump for this test, refer to FUELPUMP REPLACEMENT in this section.Disconnect outlet hose from fuel pump.Install fuel pressure gauge (P/N 529 035 591) betweendisconnected hose (inline installation).F02B0BAFUEL PRESSURE GAUGE (P/N 529 035 591)F18R08A 2TYPICAL1. Hose disconnected from fuel pump2. In-line installation of fuel pressure gaugeInstall safety lanyard and observe fuel pressure. Donot crank engine. Repeat twice. Release pressureusing B.U.D.S. between tests so that the gauge is“reset” to zero (0).FUEL PRESSURE(when installing safety lanyard)303 kPa (44 PSI)Crank or start engine and observe fuel pressure.The fuel pressure should be the same as above.If pressure is within limits, fuel pump and pressureregulator are working adequately.A rapid pressure drop indicates leakage either fromthe fuel rail or from the fuel pump check valve.Check fuel rail for leaks. If it is not leaking then replacefuel pump.A slow pressure drop indicates leakage either fromthe fuel injector or from the fuel pressure regulator.Check fuel injector for leaks (see below). If it is notleaking then replace fuel pump module.Release fuel pressure in the system using B.U.D.S.Look in the Activation tab.Remove pressure gauge and reinstall fuel hose. WARNINGWipe off any fuel spillage in the bilge. Fuel isflammable and explosive under certain conditions.Always work in a well ventilated area.1Reinstall removed parts.LMR2004-016_05_03A.FM 05-03-9

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)FUEL SYSTEM PRESSURIZATION WARNINGWhenever doing any type of repair on boat orif any components of the fuel system are disconnected,a pressure test must be done beforestarting engine and/or releasing boat tocustomer.CAUTION: Check fuel line ends for damage. Alwaystrim damaged end(s) before reinstallation.12Pressure TestProceed as follows:– Fill up fuel tank.– Remove fuel cap from chain. Ensure to removechain at fuel cap end only.F21F04ATYPICAL1. Remove chain at fuel cap end only– Place chain in filler neck for later retrieval.– Thread pressure test cap (P/N 529 035 870) intofiller neck.– Connect pump gauge tester (P/N 529 021 800from kit P/N 295 500 352) to pressure test cap.– Pressurize fuel system to 34 kPa (5 PSI).1F21F05ATYPICAL1. Pressurized to 34 kPa (5 PSI)2. Pressure test cap– If pressure is not maintained, locate leak andrepair/replace leaking component. To ease leaksearch, spray a solution of soapy water on components.Bubbles will indicate leak location.Check that leak does not come from improperlysealed hoses.NOTE: To minimize time of fuel system pressurization,the fuel tank should be quite full. The systemmust maintain a pressure of 34 kPa (5 PSI) for10 minutes. Never pressurize over 34 kPa (5 PSI). WARNINGIf any leak is found, do not start the engine. Removeany fuel leakage. Failure to correct a leakcould lead to an explosion. Do not use electricpoweredtools on boat unless system has beenverified for no leaks.Remove pressure test cap and retrieve chain fromfiller neck.Reconnect chain to fuel cap and firmly tighten fuelcap into filler neck.Electrical TestWhen connecting the safety lanyard to the DESSpost, the fuel pump should run for 2 seconds tobuild up the pressure in the system.If the pump does not work, disconnect the plugconnector from the fuel pump.05-03-10 LMR2004-016_05_03A.FM

Subsection 03Section 05 ENGINE MANAGEMENT (4-TEC)(COMPONENT INSPECTION AND ADJUSTMENT)Install a temporary connector to the fuel pump withwires long enough to make the connection outsidethe bilge and apply voltage (12 V) to this test harness.If pump does not run, replace the fuel pump module.Otherwise, probe terminals A and D of fuel pumpconnector on vehicle harness side. When installingsafety lanyard, you should read battery voltage forapproximately 2 seconds (then voltage will drop toapproximately 11 V). If battery voltage is read, theproblem can be in harness or in fuel pump connector.Repair or replace appropriate part.If battery voltage is not read, probe pin A and batteryground.a. If battery voltage is read, check continuity of circuitB-29 going towards ECM ECU. If it is good,try a new ECM ECU.b. If battery voltage is not read, check continuity ofcircuit going towards fuse block. If it is good, trya new fuse block.Fuel Pump ReplacementNOTE: Check fuel pump fuse first.RemovalUnsnap port and starboard rear seat cushions, lift,remove and carefully store for reinstallation.Remove port and starboard rear storage tubs fromdeck and carefully store for reinstallation.2F13F03A1TYPICAL1. Disconnect inlet hose2. Disconnect electrical connector3. Disconnect fuel pump connecting hose3Remove fuel pump retaining nuts.Remove fuel pump from fuel tank.InstallationFor installation, reverse the removal process butpay attention to the following.Gasket fits on mounting bracket only one way withgasket tab tell-tale in the up position. Align arrowof fuel pump with gasket tab.Refer to following illustration for tightening sequence.Torque to 2.5 N•m (22 lbf•in).216371158132 9F13L1WATYPICAL1. Remove these screws from port and starboard tubsRelease the fuel pressure in the system usingB.U.D.S. Look in the Activation tab.Disconnect electrical connector.Disconnect inlet hose from fuel pump.Disconnect either side of hose connecting fuelpumps.F04F1QA4 12TIGHTENING SEQUENCE11Perform a pressure test on fuel tank. Refer to FUELSYSTEM section.10LMR2004-016_05_03A.FM 05-03-11

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)FUEL RAILPressure at fuel rail is supplied and controlled bythe fuel pump module. Refer to FUEL PUMP forpressure test.Fuel Rail ReplacementRemovalRemove fuel rail cover from the engine.Release the fuel pressure in the system usingB.U.D.S. Look in the Activation tab.Insert pointed tools each side.Disconnect fuel hose at the connector.R1503motr162A1. Insert pointed tools each sideWrap a rag around the hose end to prevent rail draining.R1503motr163A1. Fuel injector connectors11Disconnect wiring harness from the three fuel injectors.Cut locking ties and remove the wiring harnessfrom the fuel rail.Unscrew rail retaining screws.Gently pull rail up by hand, working each side slightlyat a time.Pull rail out with fuel injectors.If necessary remove fuel injectors as describedbelow.InstallationFor installation, reverse the removal process butpay attention to the following.A thin film of injection oil should be applied to O-ringsof fuel injectors to ease installation in intake manifold.Apply Loctite 243 on rail retaining screws thentorque to 10 N•m (89 lbf•in).When installing fuel line connector to the fuel rail,put some oil on the O-ring to ease installation. WARNINGPerform a fuel pressure test and ensure thatthere is no leak. Refer to FUEL PUMP above.Run engine and check for leaks.FUEL INJECTORLeakage TestTo perform a leakage test, the injectors and fuelrail have to be removed from the engine. Refer toREMOVAL in FUEL RAIL REPLACEMENT for theprocedure.NOTE: Do not detach injectors from the fuel rail.Reconnect the fuel line and the wiring harness.Place each injector in a clean bowl.Install the safety lanyard cap on the DESS post toactivate the fuel pump.Check for fuel leakage from the injector nozzle.There should be less than 1 drop per minute. Performthe test for 2 minutes.If not within specification, replace the fuel injector(s).The leakage test is validated when performing theFUEL DELIVERY SYSTEM DIAGNOSTIC FLOWCHART elsewhere in this section.05-03-12 LMR2004-016_05_03A.FM

Subsection 03Section 05 ENGINE MANAGEMENT (4-TEC)(COMPONENT INSPECTION AND ADJUSTMENT)Electrical TestSafety lanyard must be on DESS post.Using the vehicle communication kit (VCK) withB.U.D.S., energize the fuel injector from the Activationsection.If the injector does not work, disconnect the plugconnector from the injector.Install a temporary connector to the injector withwires long enough to make the connection outsidethe bilge and apply voltage (12 V) to this testharness.This will validate the injector mechanical and electricaloperation.If it does not work, replace it.Using B.U.D.S., activate injector while probing pin2 (of injector on harness side) and battery ground.a. If 12 V is read, check continuity of circuit as perfollowing table. If it is good, try a new ECMECU.CIRCUIT NUMBER(ECM ECU connector “A“)INJECTORNUMBERA-15 1A-33 2A-14 3b. If it does not read 12 V, check continuity of circuitas per following table. If it is good, try a newVCM.CIRCUIT NUMBER(fuse block connector “B“)INJECTORNUMBERB-C 1B-D 2B-G 3Otherwise, check the resistance of the fuel injectorcircuit.Reconnect the injector and disconnect the ECMECU connector A ECM ECU.Using a multimeter, check resistance value betweenterminals as follows.R1503motr192AENGINE CONNECTORR1503motr193A12 3ECM ECU CONNECTORCOMPONENTFuel injectorcylinder 1Fuel injectorcylinder 2Fuel injectorcylinder 3CONTACT LOCATION1 (engine connector) and A-15(ECM ECU connector)2 (engine connector) and A-33(ECM ECU connector)3 (engine connector) and A-14(ECM ECU connector)The resistance should be between 11.4 and 12.6 Ω.If resistance value is correct, try a new ECM ECU.Refer to ECM ECU REPLACEMENT procedureselsewhere in this section.If resistance value is incorrect, repair the wiringharness/connectors or replace the wiring harnessbetween ECM ECU plug connector and fuel injector.3315414LMR2004-016_05_03A.FM 05-03-13

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)Fuel Injector ReplacementRemovalBefore removing the injectors, the fuel rail has tobe removed from the engine. Refer to REMOVALin FUEL RAIL REPLACEMENT for the procedure.3R1503motr164AFUEL RAIL ASS’Y1. Fuel injector2. Injector clip3. O-ring21Then remove the injector clip. Now the fuel injectorcan be easily pulled out of the fuel rail.InstallationFor the installation, reverse the removal procedure.Pay attention to the following details:Install new O-rings, if you reinstall a used injectorthen insert the fuel injector in place with yourhand. Do not use any tool. Ensure clip and injectorare properly installed.NOTE: A thin film of engine oil should be appliedto O-rings to ease insertion in rail.Apply Loctite 243 on rail retaining screws thentorque to 10 N•m (89 lbf•in). WARNINGPerform a fuel pressure test and ensure thatthere is no leak. Refer to FUEL PUMP above.Run engine and check for leaks.ELECTRONIC MANAGEMENTECM ECU AND VCMREPLACEMENTGeneralPrior to replacing a suspected ECM ECU or VCM,ensure that all the recommendations in the generalintroduction of this section have been followed.IMPORTANT: When the ECM ECU is replaced,the safety lanyard(s) and the Closed Throttle andIdle Actuator must be reprogrammed/reset. Referto their specific section for adjustment.To allow transferring previously recorded informationfrom the old ECM ECU to the new one, usethe vehicle communication kit (VCK) with B.U.D.S.Use Replace ECM in the ECU menu. Follow instructionsin its Help system.NOTE: If the old ECM ECU is working, it must beread inside B.U.D.S. prior to removing it from thevehicle to carry vehicle information and history tothe new ECM ECU.ECM ECU ReplacementDisconnect battery cables. WARNINGBattery BLACK negative cable must alwaysbe disconnected first and connected last.Disconnect both ECM ECU connectors from ECMECU.21R1503motr180A21. ECM ECU2. Retaining screws05-03-14 LMR2004-016_05_03A.FM

Subsection 03Section 05 ENGINE MANAGEMENT (4-TEC)(COMPONENT INSPECTION AND ADJUSTMENT)Unscrew all retaining screws and remove the engineECM ECU from intake manifold.Install the new ECM ECU to the engine.Reconnect ECM ECU connectors to ECM ECUthen battery cables.Transfer the data from the previous ECM ECU tothe new one using B.U.D.S. then proceed with therequired resets and reprogram safety lanyard(s), ifyou were unable to transfer the data.NOTE: If data cannot be transferred, manually enterinformation in Vehicle tab.After performing the required resets, ensure toclear all faults from the newly replaced ECM ECU.Start the engine and increase engine speed above5000 RPM to be sure no fault appears.VCM ReplacementDisconnect battery cables. WARNINGBattery BLACK negative cable must alwaysbe disconnected first and connected last.F04H7AATYPICALPull VCM out.Install the new VCM in vehicle.ENGINE WIRING HARNESS321201918R1503motr199A4171.ECM ECU connector2.CTS connector3.EGT connector4.CAPS connector5.Fuel injector connector (cylinder 1)6.Ignition coil connector (cylinder 1)7.Fuel injector connector (cylinder 2)8.Ignition coil connector (cylinder 2)9.Fuel injector connector (cylinder 3)10.Ignition coil connector (cylinder 3)11.TOPS valve connector12.OSPS connector13.TPS connector14.Idle bypass valve connector15.MATS connector16.Engine connector17.MAPS connector18.OPS connector19.KS connector20.CPS connectorResistance Test5 6 8 716Check continuity of the circuits according to thewiring diagram in the WIRING DIAGRAMS sectionof this manual.If wiring harness is good, check the respectivesensor/actuator as described in this section.Otherwise, repair the connectors, replace the wiringharness or the ECM ECU/VCM as diagnosed.1091112131415LMR2004-016_05_03A.FM 05-03-15

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)RemovalRemove fuel rail cover.Disconnect the wiring harness from all sensors/actuators.Disconnect the ECM ECU connector from the ECMECU.Cut all tie raps which are holding the wiring harnessin position.Lead the cable bundle with the injector and ignitioncoil connectors to the fuel rail and fix it also byusing 4 locking ties.11R1503motr202AR1503motr200A1. Wiring harnessRemove complete wiring harness.Installation1First connect the ECM ECU connector A to the ECMECU and fix the harness on the wiring support witha locking tie.1. Locking tiesConnect the fuel injectors, ignition coils, CAPS,CTS and EGT to the wiring harness. WARNINGPay attention not to mix injectors or ignitioncoils wires between cylinders. The location ofthe splice connectors indicate which cylinderwires belong to.Install the engine connector on the appropriatebracket on the wiring support.Then fix the other bundle on the appropriate supportson the wiring support and the ECM ECUbracket with locking ties.R1503motr201A1. Locking tie11R1503motr203A1. Locking ties05-03-16 LMR2004-016_05_03A.FM

Subsection 03Section 05 ENGINE MANAGEMENT (4-TEC)(COMPONENT INSPECTION AND ADJUSTMENT)Connect the CPS, KS, OPS, and the MAPS to thewiring harness.Also connect now the MATS, TPS, OSPS, idle bypassand TOPS valve to the wiring harness.Fix the wiring for the MATS with a locking tie tosupport the cables.R1503motr204A1. Locking tieInstall all remaining parts, which have been removed.THROTTLE POSITION SENSOR(TPS)General1The throttle position sensor (TPS) is a potentiometerthat sends a signal to the ECM ECU which isproportional to the throttle shaft angle.1IMPORTANT: Prior to testing the TPS, ensure thatmechanical components/adjustments are adequateaccording to THROTTLE BODY in AIR INDUCTIONSYSTEM above.The ECM may generate several fault codes pertainingto the TPS. Refer to SYSTEM FAULTCODES in DIAGNOSTIC PROCEDURES sectionfor more information.Wear TestWhile engine is not running, activate throttle andpay attention for smooth operation without physicalstops of the cable.Using the vehicle communication kit (VCK) withB.U.D.S., use the Throttle Opening display underMonitoring.Slowly and regularly move the throttle. Observethe needle movement. It must change graduallyand regularly as you move the throttle. If the needle“sticks”, bounces, suddenly drops or if any discrepancybetween the throttle movement and theneedle movement is noticed, it indicates a wornTPS that needs to be replaced.Voltage TestCheck the voltage output from ECM ECU to thedesired throttle position sensor.321R1503motr167AR1503motr165A1. Throttle position sensor (TPS)TPSDisconnect plug connector from throttle positionsensor. To unlock connector, insert a small screwdriverbetween the folded tab. To see the connectorpin-out, temporarily remove the connectorshield joining the harness, to expose the pin numbers.Connect a voltmeter between pin 1 and 3 andalso between pin 1 and 2 in the wiring harness.LMR2004-016_05_03A.FM 05-03-17

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)Remove and reinstall the safety lanyard to activatethe ECM ECU.Check the voltage readings as follows.CONNECTIONPin 1 with engine groundPin 2 with engine groundPin 3 with engine groundIf voltage test is good, replace the TPS.If voltage test is not good, check the resistance ofthe TPS circuit.Resistance TestReconnect the TPS.Disconnect the ECM ECU connector A on the ECMECU.2524VOLTAGE0 V5 V4.75 - 5 VNow check the resistance with the throttle platein wide open position.The resistance should be 2600 - 2700 Ω.NOTE: When measuring between pins A-24 andA-39, resistance value decreases while depressingthrottle lever. When measuring between pinsA-24 and A-25, resistance value increases whiledepressing throttle lever. The resistance valueshould change smoothly and proportionally tothrottle movement. Otherwise, replace TPS.If resistance values are correct, try a new ECM ECU.Refer to ECM ECU REPLACEMENT procedureselsewhere in this section.If resistance values are incorrect, repair connectoror replace the wiring harness between ECM ECUconnector and the TPS.ReplacementRemove the throttle body as described above.Loosen two screws retaining the TPS.Remove TPS.R1503motr191A391Using a multimeter, check resistance value betweenterminal A-25 and A-39.The resistance should be 1600 - 2400 Ω.Check the resistance between terminal A-24 andterminal A-39 with the throttle plate in idle position.The resistance should be approximately 2500 Ω.Check the resistance between terminal A-24 andterminal A-39 with the throttle plate in wide openposition.The resistance should be 1000 - 1100 Ω.Check the resistance between terminal A-24 andA-25 with throttle plate in idle position.The resistance should be 1000 - 1100 Ω.R1503motr168ATHROTTLE BODY1. Throttle position sensor (TPS)2. ScrewsApply Loctite 243 on screw threads, install the newTPS.Reinstall remaining removed parts.Proceed with the closed throttle and idle actuatorreset. See below.205-03-18 LMR2004-016_05_03A.FM

Subsection 03Section 05 ENGINE MANAGEMENT (4-TEC)(COMPONENT INSPECTION AND ADJUSTMENT)Closed Throttle and Idle Actuator ResetNOTE: This operation performs a reset of the valuesin the ECM ECU.This reset is very important. The setting of the TPSwill determine the basic parameters for all fuelmapping and several ECM ECU calculations andthe setting of the idle bypass valve will determinethe basic parameters for the idle speed control ofthe engine.NOTE: Reset must be done each time the throttleposition sensor (TPS) or the idle bypass valve isloosened or removed or throttle body is replacedor ECM ECU is replaced.CAUTION: An improperly set TPS or idle bypassvalve may lead to poor engine performanceand emission compliance could possiblybe affected.Use the vehicle communication kit (VCK) withB.U.D.S. to perform this adjustment.Ensure the throttle body plate stop lever restsagainst its stopper. Open throttle approximatelyone quarter then quickly release. Repeat 2 - 3times to settle throttle plate. If stopper does notrest against its stop lever, perform throttle cableadjustment. Refer to THROTTLE BODY in AIR IN-DUCTION SYSTEM above.Push the Reset button in the Setting section ofB.U.D.S.NOTE: No message will be displayed if operationis good. If operation is wrong, an error messagewill be displayed.NOTE: There is no idle speed adjustment to perform.The ECM ECU takes care of that. If TPS isnot within the allowed range while resetting theClosed Throttle and Idle Actuator, the ECM ECUwill generate a fault code and will not accept thesetting.Start engine and make sure it operates normallythrough its full engine RPM range. If fault codes appear,refer to SYSTEM FAULT CODES in DIAGNOS-TIC PROCEDURES section for more information.IDLE BYPASS VALVEAn idle bypass valve with good resistance measurementcan still be faulty. It is also possible thata mechanical failure occurs which is not detectablewithout measuring the air flow. Replacing theidle bypass valve may be necessary as a test.Resistance TestDisconnect idle bypass valve from the wiring harness.Using a multimeter, check the resistance in bothwindings.Check the resistance between pin A and pin D andalso between pin C ad pin B of the idle bypassvalve.The resistance in each winding should be approximately50 Ω at 23°C (73°F).If the resistance of one or both windings is notgood, replace the idle bypass valve.If resistance test of valve windings is good, checkcontinuity of circuits A-35, A-36, A-37, A-38.Visual InspectionRemove idle bypass valve from throttle body.Check the piston and bypass channel for dirt/deposits which can cause a sticking piston.CAUTION: Do not try to operate the piston of theidle bypass valve when it is dismounted. Also donot move the piston by hand. The screw drive isvery sensitive and will be destroyed.Clean the parts and install the idle bypass valve onthe throttle body.Proceed with the closed throttle and idle actuatorreset. See above.CRANKSHAFT POSITIONSENSOR (CPS)R1503motr169A1. CPS connector1LMR2004-016_05_03A.FM 05-03-19

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)NOTE: Take into account that a CPS fault can betriggered by bent or missing encoder wheel teeth.First check fault codes then check the teeth conditionif necessary. See below.Disconnect CPS wiring harness connector. Probeterminals coming from CPS while cranking engine.Voltage should be within 1-2 Vac. Otherwise,inspect wiring and replace CPS if wiring is good.ReplacementDisconnect connectors and remove the PTO cover.Refer to PTO HOUSING/MAGNETO in ENGINEsection.Remove CPS.1Resistance TestDisconnect the CPS plug connector from the wiringharness and check the resistance of the sensor itself.The resistance should be between 190 Ω and 290 Ω.Otherwise, replace the CPS.If resistance tests good, reconnect the CPS anddisconnect the ECM ECU connector A on the ECMECU.5R1503motr170AR1503motr182AUsing a multimeter, recheck resistance value betweenterminals 5 and 19.If resistance value is correct, try a new ECM ECU.Refer to ECM ECU REPLACEMENT procedureselsewhere in this section.If resistance value is incorrect, repair the connectorsor replace the wiring harness between ECMECU connector and the MATS.191. CPS inside PTO coverApply Loctite 243 on screw threads then install thenew CPS. Torque to 10 N•m (89 lbf•in).Reinstall remaining removed parts.Encoder Wheel InspectionTo check the encoder wheel for bent teeth, proceedas follows.Remove PTO cover. Refer to PTO HOUSING/MAGNETO in ENGINE section.Install a dial indicator on crankcase casting. Positionthe gauge on a tooth and set it to zero (0).Rotate flywheel and check needle movement. Themaximum allowed difference between teeth is0.15 mm (.006 in). Otherwise, straighten the toothor replace the encoder wheel.05-03-20 LMR2004-016_05_03A.FM

Subsection 03Section 05 ENGINE MANAGEMENT (4-TEC)(COMPONENT INSPECTION AND ADJUSTMENT)2Probe pin 3 of CAPS connector (wiring harnessside) and battery ground.a. If 12 V is read, check continuity of circuits A-20and A-34. If they test good, perform the CAPSvoltage test as explained below. If CAPS testsgood, try a new ECM ECU.20R1503motr177A 11. Encoder wheel2. Dial indicatorProperly reinstall cover.CAMSHAFT POSITION SENSOR(CAPS)R1503motr183AECM ECU CONNECTORb. If 12 V is not read, check continuity of connector B,pin A of engine fuse block to the CAPS. If it testsgood, try a new engine fuse block. Otherwise, repairwiring harness.Remove the CAPS from the cylinder head.Set up the following electric circuit to perform thevoltage test.34321R1503motr178A11. CAPSVoltage Test (harness)Disconnect the connector from the wiring harness.To see the connector pin-out, temporarily removethe connector shield joining the harness, to exposethe pin numbers.Remove and reinstall safety lanyard to activate thesystem.R1503motr184ACAPS PIN-OUTLMR2004-016_05_03A.FM 05-03-21

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)1200 WVoltmeterVMANIFOLD AIR TEMPERATURESENSOR (MATS)12 V+-321CAPSR1503motr208ATouch the CAPS with a conductor (ex.: screwdriver)and look if the voltage at the multimeter switchesfrom 12 V to less than 1 V.R1503motr171A12VINTAKE MANIFOLD1. Manifold air temperature sensor (MATS)Resistance TestDisconnect the plug connector from the MATSand check the resistance of the sensor itself.The resistance should be between 2280 Ω and2740 Ω at 20°C (68°F).Otherwise, replace the MATS.If resistance tests good, reconnect the MATS anddisconnect the ECM ECU connector A on the ECMECU.7R1503motr207A1 Pin 1 Pin 2 Pin 31200 W resistor1. CAPS2. ConductorIf the voltage is not good, replace the CAPS.ReplacementUnscrew the retaining screw and replace theCAPS. Ensure to reinstall O-ring.Apply Loctite 243 (blue) on thread and torque to6N•m (53 lbf•in).R1503motr186A21Using a multimeter, recheck resistance value betweenterminals 7 and 21.If resistance value is correct, try a new ECM ECU.Refer to ECM ECU REPLACEMENT procedureselsewhere in this section.If resistance value is incorrect, repair the connectorsor replace the wiring harness between ECMECU connector and the MATS.05-03-22 LMR2004-016_05_03A.FM

Subsection 03Section 05 ENGINE MANAGEMENT (4-TEC)(COMPONENT INSPECTION AND ADJUSTMENT)ReplacementDisconnect the connector of the MATS.Screw MATS out and install the new one. Torqueto 18 N•m (159 lbf•in).COOLANT TEMPERATURESENSOR (CTS)If resistance value is correct, try a new ECM ECU.Refer to ECM ECU REPLACEMENT procedureselsewhere in this section.If resistance value is incorrect, repair the connectorsor replace the wiring harness between ECMECU connector and the CTS.ReplacementRemove the fuel rail cover.Disconnect CTS connector and remove CTS.Install the new CTS and torque to 18 N•m (159 lbf•in).Reinstall remaining removed parts.MANIFOLD AIR PRESSURESENSOR (MAPS)R1503motr172A11. Coolant temperature sensor (CTS)Resistance TestDisconnect the plug connector from the CTS andcheck the resistance of the sensor itself.The resistance should be between 2280 Ω and2740 Ω at 20°C (68°F).Otherwise, replace the CTS.If resistance tests good, reconnect the CTS anddisconnect the ECM ECU connector A on the ECMECU.11R1503motr173A1. Manifold air pressure sensor (MAPS)NOTE: This sensor is a dual function device. Whenengine is started and it runs at idle speed, the sensortakes the atmospheric pressure and stores it inthe ECM ECU. Thereafter, it takes the manifold airpressure at operating RPMs.Ensure sensor is correctly installed on intake manifold.Otherwise, the MAPS could generate a faultcode for an unexpected sensor range at idle whenit reads the atmospheric pressure. Remove sensorand check for oil or dirt on its end and if problempersists, check throttle plate condition/position andthe wiring harness. Perform the following tests.1R1503motr187A27Using a multimeter, recheck resistance value betweenterminals 11 and 27.LMR2004-016_05_03A.FM 05-03-23

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)Voltage TestCheck the voltage output from ECM ECU to themanifold air pressure sensor (MAPS).Disconnect plug connector from maps and connecta voltmeter between pin 1 and 3 and alsobetween pin 1 and 2 of wiring harness.Remove and reinstall the safety lanyard to activatethe ECM ECU. There should be 5 Vdc in each test.If voltage test is good, replace the MAPS.If voltage test is not good, check the continuity ofthe MAPS circuit.Resistance TestDisconnect the ECM ECU connector A on the ECMECU.Using a multimeter, check continuity of circuits 12,28 and 40.If wiring harness is good, try a new ECM ECU.Refer to ECM ECU REPLACEMENT procedureselsewhere in this section.Otherwise, repair the connectors or replace thewiring harness between ECM ECU connector andthe MAPS.ReplacementDisconnect MAPS connector and remove the MAPS.Install the new MAPS paying attention to index itstab into the adaptor notch. Apply Loctite 243 (blue)on screw then torque to 10 N•m (89 lbf•in).EXHAUST GAS TEMPERATURESENSOR (EGT)Resistance TestDisconnect the plug connector from the EGT andcheck the resistance of the sensor itself.The resistance should be between 2280 Ω and2740 Ω at 20°C (68°F).Otherwise, replace the EGT.If resistance tests good, reconnect the EGT anddisconnect the ECM ECU connector A on the ECMECU.Using a multimeter, recheck resistance value betweenterminals 10 and 26.If resistance value is correct, try a new ECM ECU.Refer to ECM ECU replacement procedures elsewherein this section.If resistance value is incorrect, repair the connectoror replace the wiring harness between ECMECU connector and the EGT.ReplacementDisconnect EGT connector and remove EGT.Apply Loctite 518 on threads of the EGT then install.Replug connector.KNOCK SENSOR (KS)12R1503motr174A11. Knock sensor (KS)F18D2IATYPICAL1. Muffler2. Exhaust gas temperature sensor (EGT)05-03-24 LMR2004-016_05_03A.FM

Subsection 03Section 05 ENGINE MANAGEMENT (4-TEC)(COMPONENT INSPECTION AND ADJUSTMENT)Dynamic TestUsing the vehicle communication kit (VCK) withB.U.D.S., monitor the knock sensor using the Faultssection.Start the engine and bring engine RPM above5000 RPM. If no fault code occurs, the knock sensoris good.Otherwise, do the following.Ensure sensor and head contact surfaces areclean and mounting bolt and washer are correctand properly torqued down.NOTE: It is necessary to remove intake manifoldto inspect contact surfaces. Refer to INTAKE SYS-TEM section.Check the knock sensor resistance.Disconnect the connector from knock sensor harness.ReplacementRemove the intake manifold. Refer to INTAKEMANIFOLD REPLACEMENT in INTAKE section.Unscrew and remove knock sensor.Clean contact surface, apply Loctite 243 in threadedhole then install the new knock sensor.Torque screw to 24 N•m (18 lbf•ft).CAUTION: Improper torque might prevent sensorto work properly and lead to severe damageof internal engine components.Replug connector.OIL PRESSURE SWITCH (OPS)Static Resistance TestUsing a multimeter, check the resistance betweenboth terminals on the knock sensor harness side.The resistance should be approximately 5 MΩ.If resistance is not good, replace knock sensor.If resistance is good, reconnect the knock sensorconnector and disconnect the ECM ECU connectorA from the ECM ECU.R1503motr188A923Using a multimeter, recheck resistance value betweenterminals 9 and 23.If wiring harness is good, try a new ECM ECU. Referto ECM ECU REPLACEMENT procedures elsewherein this section.Otherwise, repair the connector or replace the wiringharness between ECM ECU connector andknock sensor.R1503motr194A1. OPSOil Pressure Test1To check the function of the oil pressure switch, anoil pressure test has to be performed. Refer to OILPRESSURE TEST in LUBRICATION SYSTEM section.If the engine oil pressure is out of specifications,check the points described in TROUBLESHOOT-ING section.If the engine oil pressure is good, check the resistanceof the OPS while engine is off and while engineis running.LMR2004-016_05_03A.FM 05-03-25

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)Resistance TestDisconnect the plug connector from the OPS anduse a multimeter to check the resistance betweenOPS pin and engine ground while engine isstopped (without oil pressure) and while engine isrunning (with oil pressure).When engine is stopped the resistance is infinitelyhigh (normally open switch).When engine is running and the oil pressure reaches180 - 220 kPa (26 - 32 PSI), the resistance ofthe OPS is close to 0 Ω.If resistance values are incorrect, replace OPS.If the values are correct, check the continuity ofthe wiring harness.Disconnect the ECM ECU connector A from theECM ECU and check continuity of circuit 6.6OIL SEPARATOR PRESSURESWITCH (OSPS)R1503motr189A1. OSPSTOPS Pressure Test1R1503motr195AIf wiring harness is good, try a new ECM ECU. Referto ECM ECU REPLACEMENT procedures elsewherein this section.Otherwise, repair the connector or replace the wiringharness between ECM ECU connector and OPS. WARNINGThe TOPS system might be pressurized. Whenthe TOPS valve is disconnected from the wiringharness, never open the oil filler cap. Stopthe engine and wait at least 30 seconds beforeopening it, to release the pressure.To check the function of the oil separator pressureswitch, disconnect the TOPS valve and perform aTOPS pressure test. Refer to TOPS PRESSURETEST in LUBRICATION SYSTEM section.If the engine blow-by pressure does not reach40 kPa (6 PSI), check the points described in theillustration shown on following page.Otherwise, check the resistance of the OSPSwhile engine is off and while engine is running.05-03-26 LMR2004-016_05_03A.FM

Subsection 03Section 05 ENGINE MANAGEMENT (4-TEC)(COMPONENT INSPECTION AND ADJUSTMENT)Resistance TestDisconnect the plug connector from the OSPS anduse a multimeter to check the resistance betweenOSPS pin and engine ground while engine isstopped (without blow-by pressure) and while engineis running (with blow-by pressure).When engine is stopped and the blow-by pressureis released, the resistance of the OPS is close to0 Ω (normally closed switch).When engine is running and the blow-by pressureexceeds 40 kPa (6 PSI), the resistance is infinitelyhigh.If resistance values are incorrect, replace OSPS.If the values are correct, check the continuity ofthe wiring harness.Disconnect the ECM ECU connector A from theECM ECU and check continuity of circuit 31.R1503motr198A31If wiring harness is good, try a new ECM ECU.Refer to ECM ECU REPLACEMENT procedureselsewhere in this section.Otherwise, repair the connector or replace the wiringharness between ECM ECU connector and OPS.LMR2004-016_05_03A.FM 05-03-27

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)TOPS VALVE (blow-by)TOPS DIAGNOSTIC FLOW CHARTConnect safetylanyardTOPS valve opens(short knocking noise)NoRepair orreplaceYesInstall oil pressure gaugeon oil dipstick tubeCheckwiring harnessOKFailsStart engineCheck output voltageon wiring harnessLower than 8 VPressure dropsdown directly afterreaching 40 kPa (5.8 PSI)(TOPS valve opens again)NoPressure stays below40 kPa (5.8 PSI) for 10 min.(TOPS valve is open)ReplaceTOPS valveGreater than 8 VCheck fuse 1 onengine fuse blockNoYesRetestCheckOSPSFailsOKFailsYesWorking ?YesNoTry a newECM ECUReplaceOSPSRetestOKTOPS OKRetestR1503motr275S05-03-28 LMR2004-016_05_03A.FM

Subsection 03Section 05 ENGINE MANAGEMENT (4-TEC)(COMPONENT INSPECTION AND ADJUSTMENT)The valve is turned on as soon as safety lanyard isinstalled on its post. The valve opening allows ventilationof crankcase.The OSPS monitors the pressure to detect a malfunctionof this valve. If pressure rises above a presetthreshold, the valve is re-energized again andif it fails, a fault code is generated.11R1503motr181A1. Solenoid valve2. Spring3. Valve disc4. Retaining washer234 WARNINGThe spring on the TOPS valve is tensioned andcan shoot away the valve disc. Hold the valvedisc with fingers while removing the washer.R1503motr179A1. TOPS valveResistance TestDisconnect the plug connector from the TOPSvalve and check the resistance of the solenoid itself.The resistance should be between 1.27 Ω and2.47 Ω.Otherwise, replace the TOPS valve.Dynamic TestActivate the TOPS valve by installing the safety lanyardon the DESS post.If you can hear the movement of the piston (knocking),the valve works fine, otherwise follow the procedureshown in the chart on preceeding page.TOPS Valve ReplacementDisconnect the wiring harness from the TOPS valve.Remove the oil separator cover. Refer to OIL SEPA-RATOR REPLACEMENT in the LUBRICATION SYS-TEM section.Remove the valve disc and the spring on the bottomof the TOPS valve after removing the retainingwasher.Unscrew and remove the TOPS valve.Install the new valve with new gasket. Apply Loctite243 (blue) on threads and torque to 10 N•m(89 lbf•in).Reinstall remaining removed parts.IGNITION COILSR1503motr175A1. Ignition coil1LMR2004-016_05_03A.FM 05-03-29

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)NOTE: The engine fuse block energizes the primaryside of each ignition coil individually.Using the vehicle communication kit (VCK) withB.U.D.S., energize the ignition coil from the Activationsection.You should hear the spark occurring. In doubt, usean inductive spark tester or a sealed tester – availablefrom after-market tool/equipment suppliers –to prevent spark occurring in the bilge. Otherwise,perform the following checks.An ignition coil with good resistance measurementcan still be faulty. Voltage leak can occur athigh voltage level which is not detectable with anohmmeter. Replacing the ignition coil may be necessaryas a test. WARNINGNever make a spark test with spark plug removed.Flammable vapors may be present inthe bilge and ignited by a spark which couldcause an explosion.Voltage Test WARNINGWhen disconnecting coil from spark plug, alwaysdisconnect coil from main harness first.Never check for engine ignition spark from anopen coil and/or spark plug in the enginecompartment as spark may cause fuel vaporto ignite.Disconnect the plug connector from the ignitioncoil and check the voltage supplied by the enginefuse block.The voltage should be 12 V.If 12 V is NOT read, check continuity of circuits B-C,B-D, B-G of fuse block and fuse 2, 4 and 5 of enginefuse block. If it tests good, try a new fuseblock.If 12 V is read, disconnect the ECM ECU connectorA from the ECM ECU and check the continuityof appropriate circuit 41 (cylinder 1), 1 (cylinder 2)or 29 (cylinder 3).R1503motr190AECM ECU CONNECTORIf wiring harness is defective, repair the connectoror replace the wiring harness between ECM ECUconnector and the ignition coil.If wiring harness is good, test resistance of primaryand secondary winding of ignition coil.Resistance Test41 29CAUTION: Do not remove the ignition coil beforedisconnecting the connector, or the wireswill be damaged. Do not pry up ignition coilwith a screwdriver to avoid damage.Remove ignition coil from spark plug.1112R1503motr196AInstall safety lanyard on the DESS post.Check voltage between terminal 2 of ignition coilconnector on the wiring harness and battery ground.1R1503motr197A21. Spark plug terminalUsing a multimeter, check the resistance in bothprimary and secondary windings.For primary winding check the resistance betweenpin 1 and pin 2 of the ignition coil.The resistance should be between 0.85 and 1.15 Ωat 20°C (68°F).05-03-30 LMR2004-016_05_03A.FM

Subsection 03Section 05 ENGINE MANAGEMENT (4-TEC)(COMPONENT INSPECTION AND ADJUSTMENT)For secondary winding check the resistance betweenpin 1 and spark plug terminal.The resistance should be between 9.5 and 13.5 kΩat 20°C (68°F).If the resistance of one of both windings is notgood, replace the defective ignition coil.If the windings test good, try a new engine ECMECU.NOTE: Prior to inserting the ignition coil to its location,apply some silicone lubricant (P/N 293 600041) around the seal area that touches the sparkplug hole. After installation, ensure the seal seatsproperly with engine top surface. WARNINGAlways reconnect ignition coil cables at thesame spark plugs where they come from.Otherwise, severe backfire may occur withpossible damage to exhaust system components.The genuine wiring harness is designedto prevent a cable mixing by using differentcable lengths.TDC SETTING (Top Dead Center)The ECM is able to determine the exact positionof camshaft and crankshaft. That means that noTDC setting has to be performed. It is used forboth injection and ignition timings.ENGINE START/STOP SWITCHVERIFICATIONA quick operation test can be done using the vehiclecommunication kit (VCK) with B.U.D.S., using theMonitoring section. Press the start button and lookat the start button LED. It should turn on, indicatingthe starting system is working on the input side ofthe starting system (start button, engine fuse block,ECM ECU and wiring). You know now the problemis on the output side of the starting system (VCMoutput signal to starting solenoid, wiring harness goingto the solenoid and starter motor. Refer toSTARTING SYSTEM for testing procedures). Otherwise,check the input side as follows.Disconnect the start/stop switch connector. Usingan ohmmeter, connect test probes to YELLOW/RED and PURPLE wires.Measure resistance, it must be an open circuit(switch is normally open). Depress and hold switch,the ohmmeter should read lower than 200 ohms.Otherwise, replace switch. Reconnect connector.Test continuity of circuit A-7 of engine fuse block.If it is good, try a new engine fuse block. Otherwise,repair harness/connectors.Test continuity of circuit B-19 of ECM ECU. If it isgood, try a new ECM ECU. Otherwise, repair harness/connectors.SAFETY LANYARD SWITCHVERIFICATIONIf 2 short beeps are not heard when installing thesafety lanyard, refer to DIAGNOSTIC PROCE-DURES.The following continuity tests can also be performedusing an ohmmeter.Disconnect switch wires.Safety Lanyard RemovedConnect test probes to switch BLACK and BLACK/YELLOW wires. Measure resistance, there shouldbe NO continuity (open circuit).Connect one test probe to the WHITE/GRAY wireand the other test probe to the switch top terminal.Measure resistance, it must be close to 0 ohm.Connect one test probe to the BLACK wire and theother test probe to the switch ring. Measure resistance,it must be close to 0 ohm.SPARK PLUGSDisassembly WARNINGNever remove ignition coil from the sparkplug without disconnecting it from the wiringharness. Flammable vapors may be presentin the bilge and ignited by a spark whichcould cause an explosion.Disconnect the wiring harness from the ignitioncoil.Remove the ignition coil.First unscrew the spark plug one turn.Clean the spark plug and cylinder head with pressurizedair then completely unscrew.LMR2004-016_05_03A.FM 05-03-31

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 03 (COMPONENT INSPECTION AND ADJUSTMENT)Spark Plug InstallationPrior to installation make sure that contact surfacesof the cylinder head and spark plug are free ofgrime.1. Using a wire feeler gauge, set electrode gap accordingto the following chart.2. Apply anti-seize lubricant over the spark plugthreads to prevent possible seizure.3. Hand screw spark plug into cylinder head. Then,tighten the spark plug clockwise an additional1/4 turn with a proper socket.12A00E0BA1. Proper socket2. Improper socketENGINESPARKPLUGTORQUEGAPmm (in)15034-TECNGKDCPR8-EHand tighten+ 1/4 turnwitha socket0.6(.24)CRANKING SYSTEMSee above for start/stop switch and the DESS posttesting. Refer to STARTING SYSTEM section forother tests.05-03-32 LMR2004-016_05_03A.FM

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 04 (DIAGNOSTIC PROCEDURES)DIAGNOSTIC PROCEDURES 0GENERALNOTE: This procedure to be performed for eachengine.Here is the basic order suggested to diagnose asuspected engine management or fuel injectionrelated problem:– Check the chart in TROUBLESHOOTING sectionto have an overview of problems and suggestedsolutions.– Check all fuses.– Check fuel rail pressure.– Check spark plug condition.– Check fuel pump pressure.– Check all connections of the wiring harness.– Refer to COMPONENT INSPECTION AND AD-JUSTMENT section for procedures.TerminologySome documents or software use technical termsthat may be different from the ones used in thismanual. The following table will help find the equivalence.TERMS USEDIN THIS MANUALMAPS(manifold air pressuresensor)MATS(manifold airtemperature sensor)CTS(coolant temperaturesensor)TERMS USED INOTHER DOCUMENTS/SOFTWARESAPS(air pressure sensor)ATS(air temperature sensor)WTS(water temperaturesensor)EGT(exhaust gastemperature)TOPS valve(tip-over protectionsystem)Idle bypass valveOSPS(oil separator pressureswitch)Safety lanyardETS(exhaust temperaturesensor)Blow-by valve- DLA(digital linear actuator)- Idle actuator- Idle valveOTPS(oil tank pressureswitch)KeyLMR2004-017_05_04A.FM 05-04-1

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 04 (DIAGNOSTIC PROCEDURES)SELF-DIAGNOSTIC MODERefer to the following chart. For other problems, refer to COMPONENT INSPECTION AND ADJUSTMENTsection.CODED SIGNALS POSSIBLE CAUSE REMEDY2 short beeps(while installingsafety lanyard onpost).1 long beep(while installingsafety lanyard onpost).4 very short beepsevery 3 secondsinterval for 10 min.A 2 seconds beepevery minuteinterval.A 2 seconds beepevery 15 minutesinterval.• Confirms safety lanyard signal operation. Engine can be started.• Safety lanyard is recognized by the ECM ECU.• Good contact between safety lanyard andDESS post.• Bad DESS system connection.• Wrong safety lanyard.• Defective safety lanyard.• Dried salt water or dirt in safety lanyard cap.Reinstall safety lanyard cap correctly overpost.Use a safety lanyard that has been programmedfor the sport boat. If it does notwork, check safety lanyard condition withB.U.D.S. Replace safety lanyard if reporteddefective.Use another programmed safety lanyard.Clean safety lanyard cap to remove saltwater.• Defective DESS post.Refer to ENGINE MANAGEMENT section.• Improper operation of ECM ECU or defective Refer to ENGINE MANAGEMENT section.wiring harness.• Safety lanyard has been left on its post withoutstarting engine or after engine wasstopped.• High pressure in oil separator tank.• Engine coolant temperature sensor or circuitmalfunction.• Exhaust temperature sensor or circuit malfunction.• Engine oil pressure sensor or circuit malfunction.• Low pressure in oil separator tank (engine oilleak).• TOPS valve solenoid or circuit malfunction.• ECM ECU failure.• Starter solenoid circuit malfunction.• Communication link fault detected by VCM.• ECM ECU communication link message missing(detected by VCM).To prevent battery discharge, remove thesafety lanyard from its post.Refer to LUBRICATION SYSTEM section.Refer to ENGINE MANAGEMENT section.Refer to ENGINE MANAGEMENT section.Refer to ENGINE MANAGEMENT section.Refer to ENGINE MANAGEMENT section.Refer to ENGINE MANAGEMENT section.Refer to ENGINE MANAGEMENT section.Refer to ENGINE MANAGEMENT section.Refer to ENGINE MANAGEMENT section.Refer to ENGINE MANAGEMENT section.Continuous beeps. • High engine temperature coolant. Refer to COOLING SYSTEM.• High exhaust temperature.Refer to COOLING SYSTEM.05-04-2 LMR2004-017_05_04A.FM

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 04 (DIAGNOSTIC PROCEDURES)VCK(Vehicle Communication Kit)The VCK (Vehicle Communication Kit) (P/N 529035 844) is the primary tool to diagnose enginemanagement and fuel injection related problems.NOTE: The VCM programmer does not work on4-TEC models.The 4-TEC requires B.U.D.S. version 1.1 or above.B.U.D.S. diskettes are available under P/N 529 035845 and CD-ROM under P/N 529 035 886.B.U.D.S. (Bombardier Utility and Diagnostic Software)is designed to allow actuators, sensors andelectronic equipment inspection, diagnostic optionsand reset such as the closed throttle and idleactuator.For more information pertaining to the use ofB.U.D.S., use its HELP button which contains detailedinformation on its functions. WARNINGIf the computer you are using is connected tothe 110 Vac power outlet, there is a potentialrisk of electrocution when working in contactwith water. Be careful not to touch waterwhile working with the VCK.IMPORTANT: When using B.U.D.S., with the 4-TECengines, ensure that the protocol “kW2000” is properlyselected in “MPI” under “Choose protocol”.When B.U.D.S. is connected with VCM and ECMECU, the status bar shows the protocol (kW2000)and a number 1 or 2 to the right. To work with thesport boat, number 2 must be displayed.Number 2 means that 2 “ECUs” are connected(VCM and ECM ECU).F18H0XAkW2000VCM AND ECM ECU ARE CONNECTEDNumber 1 means that 1 “ECU” is connected (eitherVCM or ECM ECU). Therefore, there is a problem.Check fuses and connections.F18H0WAONLY ONE “ECU” IS WORKING. THERE IS A PROBLEMIf an “X” is shown, the safety lanyard is not installedon its post or there is a problem with both“ECUs“. Ensure VCK is working properly andcheck connections on VCK and sport boat.VCK SupplyThe VCK (MPI box) can use the sport boat powerfor its supply.The safety lanyard must be connected in order touse the sport boat as a power source.If sport boat power is used, every time the safetylanyard is taken off the DESS post, the kW2000protocol will have to be re-activated.Changes in ECM ECUAnytime a change is brought in ECM ECU throughB.U.D.S., there will be an “ECM Tracking” messagethat will say “Remove key from vehicle“.When this occurs, remove the safety lanyard fromits post and wait until the message disappears (itlasts approximately 15 seconds after lanyard removal).4-TEC SYSTEM FAULT CODESGeneralkW2000The faults registered in the VCM/ECM ECU arekept when the battery is disconnected.IMPORTANT: After a problem has been solved,ensure to clear the fault(s) in the VCM/ECM ECUusing the VCK. This will properly reset the appropriatecounter(s). This will also record that theproblem has been fixed in the VCM/ECM ECUmemory.Many fault codes at the same time will likely be aburnt fuse(s).For more information pertaining to the code faults(state, count, first, etc.) and report, refer to B.U.D.S.online help.LMR2004-017_05_04A.FM 05-04-3

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 04 (DIAGNOSTIC PROCEDURES)Supplemental Information for SomeSpecific FaultsECM ECU fault codes P0601, P0602, P0604 andP605: These codes may occur in the following situations:– Electrical noise is picked up by the ECM ECU.Ensure that all connections are in good condition,also grounds (battery, ECM ECU, engineand ignition system), they are clean and welltightened and that all electronic componentsare genuine — particularly in the ignition system.Installing resistive caps, non-resistivespark plugs or knock sensor wiring/routing maylead to generate this fault code.– Electrical noise might also lead engine to occasionalcutout without generating a fault codewhen engine is restarted. When looking at thefault code, pay attention to the “count” value inB.U.D.S. A value between 1 and 9 confirms anelectrical noise problem. A value of 10 andabove will generate a fault code.– When installing a new ECM ECU. It is not properlyprogrammed from the factory. The ECM ECUmust be returned to be properly “activated”.– If everything is in good condition, try a newECM ECU.When using the service action suggested in theFault section of B.U.D.S., the system circuits arereferred as 4-23 for instance. It means Amp connectorno. 4 and the circuit wire no. 23 as found inthe wiring diagram.When they are referred as A-41, it means connector“A” on the ECM ECU and the circuit 41.TPS (Throttle Position Sensor) FaultsFaults which are reported in B.U.D.S. fall into twogroups TPS faults and adaption faults. These aredisplayed on the B.U.D.S. system as TPS OUT OFRANGE and TPS ADAPTION FAILURE.05-04-4 LMR2004-017_05_04A.FM

Section 05 ENGINE MANAGEMENT (4-TEC)Subsection 04 (DIAGNOSTIC PROCEDURES)TPS “OUT OF RANGE” FaultIt is caused by the sensor reading going out of its allowable range. This fault can occur during the wholerange of movement of the throttle.To diagnose this fully, it is recommended to operate the throttle through its full range. It is also recommendedto release the throttle quickly as this may also show up a fault that is intermittent.POSSIBLE CAUSES RESULT ACTIONCheck if connector is disconnected from TPS. Yes • Fix.Check if sensor is loose.Yes• Fix and reset Closed Throttle and Idle Actuator.Inspect sensor for damage or corrosion.Yes• Replace and reset Closed Throttle and IdleActuator.Inspect wiring (voltage test). Failed • Repair.Inspect wiring and sensor (resistance test).Test sensor operation (wear test).Failed• If bad wiring, repair.• If bad TPS, replace and reset Closed Throttleand Idle Actuator.• Replace and reset Closed Throttle and IdleActuator.TPS “ADAPTATION FAILURE” FaultIt is caused by the idle position moving out of an acceptable range.Following failures can be effected by a TPS “Adaption Failure“:– Idle speed is out of range.– Engine stops, when throttle is released quickly.– Engine runs inconsistent in low partload or low RPM.POSSIBLE CAUSES RESULT ACTIONSensor has been replaced and TPS closed• Reset Closed Throttle and Idle Actuator.Yesposition not reset.Throttle body has been replaced and TPS• Reset Closed Throttle and Idle Actuator.Yesclosed position not reset.ECM ECU has been replaced and TPS closed• Reset Closed Throttle and Idle Actuator.Yesposition not reset.Throttle cable too tight.Sensor is loose.YesYes• Fix and reset Closed Throttle and Idle Actuator.• Fix and reset Closed Throttle and Idle Actuator.Throttle bracket is loose.Yes• Fix and reset Closed Throttle and Idle Actuator.Adjustment screw worn or loose. Yes • Change throttle body.Idle bypass valve replaced but not reset.Yes• Reset Closed Throttle and Idle Actuatorusing B.U.D.S.LMR2004-017_05_04A.FM 05-04-5

Section 06 COOLING SYSTEMSubsection 01 (TABLE OF CONTENTS)TABLE OF CONTENTS 0CIRCUIT, COMPONENTS AND CARE................................................................................... 06-02-1CIRCUIT.............................................................................................................................. 06-02-4COOLING SYSTEM LEAK TEST........................................................................................ 06-02-4INSPECTION ...................................................................................................................... 06-02-6DRAINING THE SYSTEM (port or starboard).................................................................. 06-02-6COOLANT REPLACEMENT............................................................................................... 06-02-6COOLANT PUMP HOUSING............................................................................................. 06-02-8THERMOSTAT ................................................................................................................... 06-02-9COOLANT PUMP IMPELLER ............................................................................................ 06-02-9ROTARY SEAL ................................................................................................................... 06-02-10CARE .................................................................................................................................. 06-02-12LMR2004-030_06_01ATOC.FM 06-01-1

Subsection 02Section 06 COOLING SYSTEM(CIRCUIT, COMPONENTS AND CARE)CIRCUIT, COMPONENTS AND CARE 04-TEC Engines — Closed Loop System125467148151331110912F18E0ZSLMR2004-018-06-02A.FM 06-02-1

Section 06 COOLING SYSTEMSubsection 02 (CIRCUIT, COMPONENTS AND CARE)4-TEC Engines — Open Loop SystemSTARBOARD VIEWHull25 N•m(18 lbf•ft)Loctite 243Body8 N•m(71 lbf•in)PipesealantPort sideF18E1XS06-02-2 LMR2004-018-06-02A.FM

Subsection 02Section 06 COOLING SYSTEM(CIRCUIT, COMPONENTS AND CARE)4-TEC EnginesExpansioncoolant tankCoolant temperaturesensor (CTS) activateswhen temperatureexceeds 100°C (212°F)Bleed hose fromcylinder head toexpansion coolant tankCoolant flowsto oil coolerCoolant housingincluding thermostatopens at 87°C (188°F)and coolant pumpimpellerCoolant returnsfrom oil coolerOil coolerCoolantflows to heatexchangerHeat exchangerCoolant returnsfrom heat exchangerF18E1YSTYPICALLMR2004-018-06-02A.FM 06-02-3

Section 06 COOLING SYSTEMSubsection 02 (CIRCUIT, COMPONENTS AND CARE)1503 EnginesCIRCUITClosed Loop SystemNOTE: These procedures to be performed on eachengine.A closed loop cooling system is utilized on the1503 4-TEC engines, which offers an efficient enginecooling while keeping dirt and salt water outof the cooling system. This system keeps the temperatureconstant and prevents internal enginecorrosion.A separate coolant expansion tank ensures thatenough engine coolant is in the circuit during anyoperating condition.The coolant flow comes from the coolant pumpimpeller into the engine block. It goes around thecylinders and straight up to the cylinder head. Asmaller quantity of engine coolant enters the engineblock on the exhaust side for additional cooling.In the cylinder head the water channels flowaround the exhaust and then the intake valve pocketsleaving the engine through a large hose. Fromthere the coolant goes back to the coolant pumphousing and depending on the engine temperature,it flows through the thermostat directly backto the coolant pump impeller, or it makes its waythrough the heat exchanger and back to the coolantpump.A smaller quantity of engine coolant is also directedthrough the oil cooler, located under the air intakemanifold, to increase cooling efficiency.A coolant temperature sensor and bleed nipple arelocated on the cylinder head of each engine.CAUTION: Never modify cooling system arrangement,otherwise serious engine damagecould occur.Pressure CapCheck if cap will pressurize the system. If not, installa new 90 kPa (13 PSI) cap (do not exceed thispressure).COOLING SYSTEM LEAK TEST WARNINGTo prevent burning yourself, do not removethe expansion tank cap or loosen the heat exchangerdrain plug if the engine is hot.Install test radiator cap (P/N 529 021 400) and hosepincher (P/N 295 000 076) on overflow hose. Pressurizeall system through coolant expansion tankto 90 kPa (13 PSI).1212F18E1ZATYPICAL1. Hose pincher on this hose2. Pressure pump (P/N 529 021 800)Check all hoses, heat exchanger, engine and oilcooler for coolant leaks. Spray a soap/water solutionand look for air bubbles only if performing testwith empty system.Remove hose pincher and test pressure cap.F18E0XA1. Bleed nipple2. Coolant temperature sensor (CTS)06-02-4 LMR2004-018-06-02A.FM

Subsection 02Section 06 COOLING SYSTEM(CIRCUIT, COMPONENTS AND CARE)Open Loop SystemThe water supply is provided by a pressurized areain the jet pump between the impeller and venturi.The water flow is controlled by a reducer locatedbetween the jet pump support and the jet pumpon the inlet side. The reducer is black on the 4-TECmodels.Water is directed to the exhaust manifold fittinglocated at front of manifold.Water enters exhaust pipe and flows in the waterjacket of pipe.3131F18E1FA1. Exhaust manifold2. Water inlet3. Water outlet2Water enters water jacket of the manifold frontend and is directed to the rear of exhaust manifold.Water exits exhaust manifold through 2 hoses atrear of manifold and enters exhaust pipe.321F18E1GATYPICAL1. Exhaust pipe2. Outlet holes of exhaust pipe3. MufflerThe total loss system is self-bleeding, with bleedingof the exhaust system accomplished by thebleed hose located at the upper most point of thecircuit of the exhaust pipe.Water exits exhaust pipe through holes at the endof the water jacket and mixes with exhaust gas inthe muffler.Water is expulsed from mufflers through the exhaustoutlet in transom area.2F18E1EATYPICAL1. Water coming from exhaust manifold2. Exhaust pipe3. Bleed hoseLMR2004-018-06-02A.FM 06-02-5

Section 06 COOLING SYSTEMSubsection 02 (CIRCUIT, COMPONENTS AND CARE)ClampTo cut or secure non-reusable Oetiker clamps ofcooling system hoses, use pliers (P/N 295 000 070).1DRAINING THE SYSTEM(port or starboard) WARNINGNever drain or refill cooling system when engineis hot.Remove expansion tank cap.To drain cooling system, unscrew cooling systemdrain plug at the rear of the heat exchanger.1F01B2KA21. Cutting clamp2. Securing clampINSPECTIONCheck general condition of hoses and clamp tightness.Check the weep hole for oil or coolant.F18E20ATYPICAL1. Cooling drain plugUse an appropriate container to collect coolant.Dispose of coolant as per local regulations.Reinstall drain plug.Ensure to put pipe sealant (Loctite 567) on threadsof drain plug.Torque to 8.3 N•m (73 lbf•in).COOLANT REPLACEMENTF18E1CA1. Weep holeNOTE: Coolant flowing from weep hole indicatesa damaged rotary seal. Oil out of the weep holeindicates a non- working oil seal. If any leaks aredetected, determine cause and repair.1Recommended CoolantUse a blend of 50% antifreeze with 50% water.Premixed antifreeze/water is available (P/N 293600 038).CAUTION: To prevent antifreeze deterioration orgelling, always use the same brand. Never mixdifferent brands unless cooling system is completelyflushed and refilled.06-02-6 LMR2004-018-06-02A.FM

Subsection 02Section 06 COOLING SYSTEM(CIRCUIT, COMPONENTS AND CARE)Reinstall pressure cap.CAUTION: To prevent rust formation or freezingcondition in cold areas, always replenish thesystem with 50% antifreeze and 50% water. Pureantifreeze will freeze at a higher temperaturethan the optimal water/antifreeze mix. Alwaysuse ethylene glycol antifreeze containing corrosioninhibitors specifically recommended foraluminum engines.1System CapacityPort side system uses approximately 5.2 L (5.5 U.S.quarts).Starboard side system uses approximately 4.7 L(5 U.S. quarts).Coolant Replacement Procedure WARNINGTo prevent burning yourself do not removethe expansion tank cap or loosen the rideplate drain plug if the engine is hot.Drain the system completely as described above.Sport boat should be level, and engine cold for refilling.NOTE: Test the density of the coolant using an antifreezehydrometer. Follow hydrometer manufacturerinstructions for proper use.The reading should be some degrees below thecoldest temperature you expect in the area wherethe sport boat is to be used or stored. Add wateror antifreeze accordingly. Refill to the proper level.CAUTION: Pure antifreeze will freeze at a highertemperature than the optimal water/antifreezemix.Loosen clamp and remove hose from coolantpump housing shown in the next photo.F18E21A2TYPICAL1. Loosen this clamp2. Remove this hoseRaise hose as high as possible and fill until coolantsolution begins to run out of coolant pump housing.Quickly reinstall hose onto coolant pump housing.Torque clamp to 3 - 5 N•m (26.5 - 44 lbf•in).Clean excess coolant from bilge.Dispose of coolant as per local regulations.Remove coolant expansion tank pressure cap andadd coolant.Fill expansion tank to MAX line.1F18E0NA1. Level between marks when engine is coldInstall pressure cap.LMR2004-018-06-02A.FM 06-02-7

Section 06 COOLING SYSTEMSubsection 02 (CIRCUIT, COMPONENTS AND CARE)Test boat in water 10 - 15 minutes at various throttlespeeds to obtain engine operating temperature,periodically checking coolant level in coolantexpansion tanks. When the pressure cap is removedand the pressure relieved, the level in thetanks will rise as the rubber hoses contract.An alternative to water testing is as follows:Properly cool exhaust system by installing a gardenhose to flush fitting (or water test). Refer toflushing in MAINTENANCE section.Start engine and let run for 2 minutes. Stop engineand wait 15 minutes to cool down. Refill tank asnecessary.Repeat this run-stop cycle 2 - 3 times until thermostatopens and stop engine.Last, refill expansion tank and reinstall cap.When engine has completely cooled down, recheckcoolant level in radiator and coolant tank andtop off as necessary.Wipe up and remove any coolant spilled in thebilge/engine compartment.Dispose of spilled coolant per local regulations.COOLANT PUMP HOUSING– oil cooler outlet hose no. 3– screws no. 4 and no. 5 retaining coolant pumphousing no. 6– coolant pump housing no. 6.InspectionCheck if gasket no. 7 is brittle, hard or damagedand replace as necessary.F18E11A1. Weep hole pump housing gasketCheck if thermostat is in good condition. Refer toTHERMOSTAT elsewhere in this section.1InstallationThe installation is the opposite of the removal procedure.Install screws as per the following illustration.22 1111F18E0YA1. Coolant pump housingRemovalDrain cooling system and engine oil, refer to LU-BRICATION SYSTEM.Remove from housing:– heat exchanger inlet and outlet hoses– cylinder head outlet hose no. 1– oil cooler inlet hose no. 2F18E10A 111. Screw M6 x 252. Screw M6 x 105106-02-8 LMR2004-018-06-02A.FM

Subsection 02Section 06 COOLING SYSTEM(CIRCUIT, COMPONENTS AND CARE)CAUTION: To prevent leaking, take care thatthe gaskets are exactly in groove when you reinstallthe coolant pump housing.Apply Loctite 243 on screw threads and torque to10 N•m (89 lbf•in).Tightening sequence for screws on coolant pumphousing is as per following illustration.7814652F18E12A 13F18E10B 23THERMOSTATThe thermostat is a single action type.RemovalRemove the coolant pump housing from the PTOcover. Refer to COOLANT PUMP HOUSING RE-MOVAL elsewhere in this section.NOTE: The thermostat is located inside the coolantpump housing.Leak TestPlug the connections of the oil cooler return hose,coolant tank hose, heat exchanger return hose andcylinder head return hose with a rag.41. Oil cooler return connection2. Coolant tank hose connection3. Heat exchanger return hose connection4. Cylinder head return hose connectionFill the coolant pump housing with water.If a bigger quantity of coolant leaks out at the heatexchanger outlet connection, replace the coolantpump housing. Refer to COOLANT PUMP HOUS-ING in this section.If there is no leak, check the operation of the thermostat.Dynamic TestTo check the operation of the thermostat, put it inwater and heat water. Look inside the cylinderhead return hose connection to see the movementof the thermostat. Thermostat should openwhen water temperature reaches 87°C (188°F).If there is no operation, replace coolant pumphousing and thermostat.InstallationFor installation, reverse the removal procedure,paying attention to the following details.Refer to COOLANT PUMP HOUSING REPLACE-MENT in this section.COOLANT PUMP IMPELLERRemovalRemove:– coolant pump housing no. 6– unscrew the impeller no. 8 clockwise.LMR2004-018-06-02A.FM 06-02-9

Section 06 COOLING SYSTEMSubsection 02 (CIRCUIT, COMPONENTS AND CARE)F18E13A1. ImpellerCAUTION: Coolant/oil pump shaft no. 9 and impellerno. 8 have left-hand threads. Remove byturning clockwise and install by turning counterclockwise.InspectionCheck impeller for cracks or other damage. Replaceimpeller if damaged.1Coolant leaking out of the hole indicates a defectiverotary seal. Leaking oil indicates a faulty oilseal.However, if seal is disassembled both parts haveto be replaced together.RemovalRemove:– coolant pump housing no. 6CAUTION: Always unscrew the impeller clockwiseotherwise you can damage the components.– unscrew the impeller no. 8 clockwise– remove PTO cover no. 10. Refer to PTO HOUSING/MAGNETO section– remove screws no. 11 retaining oil pump cover2InstallationThe installation is the opposite of the removal procedure.Pay attention to the following details.CAUTION: Be careful not to damage impellervanes during installation.Torque impeller to 3 N•m (27 lbf•in).ROTARY SEALInspectionCheck weep hole for oil or coolant leak.1F18E14A1. Retaining screws2. Oil pump cover– remove oil pump cover no. 12– remove outer oil pump rotor no. 131F18E1CA1. Weep hole1F18E15A1. Outer oil pump rotor06-02-10 LMR2004-018-06-02A.FM

Subsection 02Section 06 COOLING SYSTEM(CIRCUIT, COMPONENTS AND CARE)– extract the coolant/oil pump shaft no. 9 fromoutside PTO housing cover with a pusher21InstallationThe installation is the opposite of the removal procedure.Pay attention to the following details.NOTE: Never use oil in the press fit area of the oilseal and rotary seal.Push water pump shaft oil seal in place by usingthumb.Install the new rotary seal using the rotary seal installer(P/N 529 035 823).CAUTION: Never use a hammer for the rotaryseal or water/oil pump shaft installation. Onlyuse a press to avoid damaging the ceramic component.F18E16A1. Pusher2. Coolant/oil pump shaft– remove rotary seal no. 14 with a screwdriver21F18E19AF18E17ACAUTION: Be careful not to damage the surfaceof the rotary seal bore in magneto housingcover.– always replace the oil seal no. 15 behind therotary seal.1. Rotary seal2. Rotary seal installerInstall the coolant/oil pump shaft using the rotaryseal installer (P/N 529 035 823) on the oppositeside to the rotary seal and the oil seal protector(P/N 529 035 82) with a press.211F18E1AA1. Oil seal protector2. Coolant/oil pump shaftF18E18A1. Oil sealLMR2004-018-06-02A.FM 06-02-11

Section 06 COOLING SYSTEMSubsection 02 (CIRCUIT, COMPONENTS AND CARE)F18E1BA1. Coolant/oil pump shaft with oil seal protector2. Rotary seal installerCAREFor flushing purposes, the exhaust cooling systemis equipped with a hose adapter.To connect to the fitting spigot. A garden hose isused to flush the whole system by backwash. Forflushing procedure, refer to FLUSHING AND LU-BRICATION.For winterization of cooling system, refer toSTORAGE.When servicing the hull, rotate sport boat eitherway (seen from the rear) maximum to 90°.Towing the Sport Boat in WaterNOTE: These procedures to be performed oneach engine.Special precautions should be taken when towinga Sea-Doo sport boat in water.Maximum recommended towing speed is24 km/h (15 MPH).When towing your sport boat in water, pinch thewater supply hose from the jet pump housing to theengine with a large hose pincher (P/N 529 032 500).12This will prevent the exhaust cooling system fromfilling which may lead to water being injected intoand filling the exhaust system and the engine.Without the engine running there isn’t any exhaustpressure to carry the water out the exhaustoutlet.CAUTION: Failure to do this may result in damageto the engine. If you must tow a strandedsport boat in water and do not have a hosepincher be sure to stay well below the maximumtowing speed of 24 km/h (15 MPH).Snugly install the hose pincher on the water supplyhose as shown in the following illustrations.F18E0RATYPICAL1. Hose pincherCAUTION: When finished towing the sportboat, the hose pincher must be removed beforeoperating the engines.1F01B23A06-02-12 LMR2004-018-06-02A.FM

Subsection 02Section 06 COOLING SYSTEM(CIRCUIT, COMPONENTS AND CARE)TECHNICAL DATATYPE:Closed and open loop cooling system.COOLANT FLOW:Pressure build-up at coolant pump.TEMPERATURE CONTROL:Thermostat.SYSTEM BLEEDING:Self-bleed type through expansion tank(hose at uppermost point of circuit).SYSTEM DRAINING:Self-drain type on the exhaust cooling system(hose at lowest point of circuit).SYSTEM FLUSHING:Required only for exhaust cooling system(open loop system).MONITORING BEEPER:Turns on at 100°C (212°F).COOLANT LIFE CYCLE:2 years.LMR2004-018-06-02A.FM 06-02-13

Section 07 FUEL SYSTEMSubsection 01 (TABLE OF CONTENTS)TABLE OF CONTENTS 0FUEL CIRCUIT........................................................................................................................ 07-02-1GENERAL ........................................................................................................................... 07-02-2REMOVAL........................................................................................................................... 07-02-2INSPECTION ...................................................................................................................... 07-02-3ASSEMBLY......................................................................................................................... 07-02-3FUEL SYSTEM PRESSURIZATION ................................................................................... 07-02-3AIR INTAKE ............................................................................................................................ 07-03-1REMOVAL........................................................................................................................... 07-03-2ASSEMBLY ........................................................................................................................ 07-03-2LMR2004-030_07_01ATOC.FM 07-01-1

Section 07Subsection 02FUEL SYSTEM(FUEL CIRCUIT)FUEL CIRCUITTo batterygroundLoctite 2717.2-8.8 N•m(63.7-77.8 lbf•in)8Loctite 2717.2-8.8 N•m(63.7-77.8 lbf•in)8Loctite 2717.2-8.8 N•m(63.7-77.8 lbf•in)Body8 832.5-3 N•m(22.1-26.5 lbf•in)274-6 N•m(35.4-53.1lbf•in)61432.5-3 N•m(22.1-26.5 lbf•in)55F13F04SLMR2004-019_07_02A.FM 07-02-1

Section 07 FUEL SYSTEMSubsection 02 (FUEL CIRCUIT)GENERAL WARNINGThe fuel system of a fuel injection system holdsmuch more pressure than on a carburetedsport boat. Prior to disconnecting a hose or toremoving a component from the fuel system,follow the recommendations described in EN-GINE MANAGEMENT under FUEL SYSTEM. WARNINGWhenever repairing the fuel system, alwaysverify for water infiltration in reservoir. Replaceany damaged, leaking or deteriorated fuellines.F01B04A 11. Securing clampWhen working with fuel, pay attention to the followingwarning. WARNINGFuel is flammable and explosive under certainconditions. Always work in a well ventilatedarea. Always wipe off any fuel spillagefrom the sport boat.To secure or cut Oetiker clamps on fuel lines, usepliers (P/N 295 000 070).F01B05A11. Securing clamp in limited accessWhen replacing fuel lines on Sea-Doo sport boat,be sure to use “A1” hoses as available fromBombardier parts department. Use hoses ass’yavailable as parts replacement only. This will ensurecontinued proper and safe operation. WARNINGUse of improper fuel lines could compromisefuel system integrity.F01B03A1. Cutting clamp1REMOVALFuel FilterThe fuel filter is located at the electric fuel pumpinlet. The pump has to be removed from the fueltank to have access to its filter. Refer to ENGINEMANAGEMENT section.07-02-2 LMR2004-019_07_02A.FM

Section 07Subsection 02FUEL SYSTEM(FUEL CIRCUIT)Electric Fuel PumpRefer to appropriate ENGINE MANAGEMENTsection.Fuel TankNOTE: It is necessary to remove the engines. Referto REMOVAL AND INSTALLATION and COM-PONENTS subsection.Siphon fuel tank no. 1.Disconnect EMS connectors.Remove TOPS switch from electrical harness.Disconnect fuel pump connections.Disconnect fuel tank filler hose no. 2.Disconnect fuel tank vent hose no. 6.Disconnect all fuel tank connections.Cut locking ties as required to release wiring harnesses.Remove fuel tank from the vehicle. WARNINGCheck that fiberglass is not exposed.INSPECTIONThe filter at fuel pump inlet is not replaceable individually.The complete fuel pump unit has to bereplaced.Fuel Filler HoseVerify fuel filler hose no. 2 for damage. Ensure thatclamps no. 3 are well-positioned and tightened.Torque clamps to 2.5 - 3 N•m (22 - 26.5 lbf•in).Fuel Tank Vent HoseVerify fuel tank vent hose no. 6 for damage. Ensurethat clamps no. 7 are well-positioned and tightened.Torque clamps to 4 - 6 N•m (35.4 - 53.1 lbf•in).ASSEMBLYAssembly is essentially the reverse of disassemblyprocedures.Install fuel pump on fuel tank and torque nuts to2.5 N•m (22 lbf•in).1 5134 12F09F0HA6TORQUE AS PER SEQUENCE3 7Ensure rubber pads no. 4 are in place.Insert tank and fasten tank straps no. 8.Properly secure harnesses.FUEL SYSTEM PRESSURIZATION WARNINGWhenever doing any type of repair on boat orif any components of the fuel system are disconnected,a pressure test must be done beforestarting engine and/or releasing boat tocustomer.CAUTION: Check fuel line ends for damage. Alwaystrim damaged end(s) before reinstallation.82 91011Fuel TankVisually inspect the outside of the fuel tank necksfor cracks. If the fuel tank is questionable, performa fuel system pressurization test.Inspect rubber pads no. 4 under tank for damageor misalignment.LMR2004-019_07_02A.FM 07-02-3

Section 07 FUEL SYSTEMSubsection 02 (FUEL CIRCUIT)Pressure TestProceed as follows:– Fill up fuel tank.– Remove fuel cap from chain. Ensure to removechain at fuel cap end only.F13F0CATYPICAL1. Remove chain at fuel cap end only1– Place chain in filler neck for later retrieval.– Thread pressure test cap (P/N 529 035 870) intofiller neck.– Connect pump gauge tester (P/N 529 021 800)from kit (P/N 295 500 352) to pressure test cap.– Pressurize fuel system to 34 kPa (5 PSI).12– If pressure is not maintained locate leak andrepair/replace leaking component. To ease leaksearch spray a solution of soapy water on components.Bubbles will indicate leak location.Check that leaks do not come from improperlysealed hoses.NOTE: To minimize time of fuel system pressurization,the fuel tank should be quite full. The systemmust maintain a pressure of 34 kPa (5 PSI) for10 minutes. Never pressurize over 34 kPa (5 PSI). WARNINGIf any leak is found, do not start the engine.Remove any fuel leakage. Failure to correct aleak could lead to an explosion. Do not useelectric-powered tools on boat unless systemhas been verified for no leaks.Remove pressure test cap and retrieve chain fromfiller neck.Reconnect chain to fuel cap and firmly tighten fuelcap into filler neck.High Pressure Test (fuel pump circuit)Refer to the appropriate ENGINE MANAGEMENTsection. WARNINGPrior to installing the safety lanyard, refer tothe appropriate ENGINE MANAGEMENT sectionfor necessary safety precautions.F13F0DATYPICAL1. Pressurized to 34 kPa (5 PSI)2. Pressure test cap07-02-4 LMR2004-019_07_02A.FM

Section 07 FUEL SYSTEMSubsection 03 (AIR INTAKE)AIR INTAKE 01442 N•m(18 lbf•in)234 N•m(35 lbf•in)F09F12STYPICALLMR2004-019_07_03A.FM 07-03-1

Section 07 FUEL SYSTEMSubsection 03 (AIR INTAKE)REMOVALNOTE: This procedure to be performed for eachengine.Air Intake SilencerTurn main battery cut-off switch to OFF position.Disconnect regulator harness connectors fromtop of air intake box no. 1, as shown below.41Loosen clamp no. 2 and remove intake hose no. 3from intake silencer.Detach straps no. 4 using hook tool (P/N 529 035559).ASSEMBLYAssembly is essentially the reverse of removalprocedures. However pay particular attention tothe following.NOTE: Air intake silencer is a sealed unit and isnot user seviceable.CAUTION: Do not modify air intake system,otherwise calibration will be affected.Replace air intake silencer inside engine compartmentand between mounting rails located at seatback.Fasten air intake silencer with straps no. 4, usinghook tool (P/N 529 035 559).Attach intake hose no. 3 to intake silencer andtighten clamp no. 2 to 2 N•m (18 lbf•in).Attach regulator harness connectors no. 1.Turn main battery cut-off switch to ON position.F13F0EA 23TYPICAL1. Regulator harness connectors2. Clamp3. Intake hose4. Straps07-03-2 LMR2004-019_07_03A.FM

Section 08Subsection 01ELECTRICAL SYSTEM(TABLE OF CONTENTS)TABLE OF CONTENTS 0CHARGING SYSTEM............................................................................................................. 08-02-1GENERAL ........................................................................................................................... 08-02-1TESTING PROCEDURE ..................................................................................................... 08-02-1BATTERY ............................................................................................................................ 08-02-2STARTING SYSTEM.............................................................................................................. 08-03-1GENERAL ........................................................................................................................... 08-03-1STARTING SYSTEM TROUBLESHOOTING..................................................................... 08-03-2STARTER REMOVAL.......................................................................................................... 08-03-3STARTER DISASSEMBLY.................................................................................................. 08-03-3CLEANING ......................................................................................................................... 08-03-4PARTS INSPECTION.......................................................................................................... 08-03-5STARTER ASSEMBLY........................................................................................................ 08-03-5STARTER INSTALLATION ................................................................................................. 08-03-6STARTER SPECIFICATION ................................................................................................ 08-03-7INSTRUMENTS AND ACCESSORIES .................................................................................. 08-04-1ADDITION OF ACCESSORIES .......................................................................................... 08-04-1INSPECTION ...................................................................................................................... 08-04-1LMR2004-030_08_01ATOC.FM 08-01-1

Section 08 ELECTRICAL SYSTEMSubsection 02 (CHARGING SYSTEM)CHARGING SYSTEM 0NOTE: This procedure to be performed for eachengine.GENERALMagnetoThe purpose of the charging system is to keep thebattery at a full state of charge.The magneto is the primary source of electricalenergy. It transforms a magnetic field into electriccurrent (AC).The magneto has a 3 phase, delta wound statoron 18 poles. Capacity is 380 watts.Rectifier/RegulatorThe rectifier receives AC current from the magnetoand transforms it into direct current (DC).The regulator, included in the same unit, limits voltageat a maximum level (14.5 to 14.8 volts) to preventany damage to components.The regulator/rectifier is a 3-phase series typewhich transforms (AC) from the magneto into (DC)to allow battery charging.BatteryThe battery is the DC source for the electric starter,the ECU/EMS and all accessories.FuseIf the battery is regularly discharged, check fusecondition.The rectifier/regulator could cause blown fuses. Tocheck, simply disconnect the rectifier/regulator fromthe circuit.If the fuse still fails, check for a defective wire.CAUTION: Do not use a higher rated fuse asthis could cause severe damage.The charging system is protected by 1 fuse (30 A)attached to the starter relay.TESTING PROCEDURENOTE: Ensure that the battery is in good conditionprior to performing the following tests. A low ordead battery will affect test results.Rectifier/RegulatorSTATIC TEST: CONTINUITYDue to internal circuitry, no static test can be done.DYNAMIC TESTCurrent TestProceed as follows:– Start engine.– Lay an inductive ammeter on positive cable ofbattery.– Bring engine to approximately 6000 RPM.Current reading should be approximately 5 amperes,depending on battery state. If not, checkmagneto output prior to concluding that rectifier isfaulty.Voltage TestProceed as follows:– Set multimeter to Vdc scale. Connect a multimeterto battery posts. Connect RED test lead topositive (+) and BLACK lead to negative (-) batteryposts.– Note the battery voltage. A fully-charged batteryshould read approximately 12.6 vdc.– Bring engine to approximately 5500 RPM.If multimeter reads over 15 volts, regulator is defective.Replace it.If the voltage reading does not rise above batteryvoltage indicated previously, the system is notcharging.NOTE: If distilled water must continually be added,it indicates an over voltage situation requiring replacementof the rectifier/regulator. If, on the otherhand, the battery does not stay charged, the problemcan come from any of the charging circuit components.If these all check good, it would be accurateto assume the problem comes from the rectifier/regulator.LMR2004-020-08-02A.FM 08-02-1

Section 08 ELECTRICAL SYSTEMSubsection 02 (CHARGING SYSTEM)StatorSTATIC TEST: CONTINUITYDisconnect the magneto wiring harness connectorand probe the three connectors.1. Check resistance between two of the YELLOWwires. The resistance should be between 0.1 to1.0 ohm.2321F04H6XATYPICAL1. Multimeter2. Magneto harness connector3. YELLOW wires32. Place either meter lead into the remaining YEL-LOW wire and note the resistance (same asstep no. 1). If the readings are out of specification,the stator will need to be replaced.STATIC TEST: INSULATIONDisconnect the magneto wiring harness connectorand probe the three connectors.1. Insert multimeter positive (+) probe to one ofthe YELLOW wires of the 3-pin magneto harnessadapter.2. Ground the multimeter negative (-) probe to theengine or the stator iron core and note the reading.F04H6YA4TYPICAL1. Multimeter2. Magneto harness adapter3. Positive (+) probe to YELLOW wire4. Negative (-) probe to ground3. Repeat test with the other two YELLOW wiresof the 3-pin magneto harness adapter.NOTE: There should be no continuity (infinity) betweenthe magneto insulated coils and ground. Ifthere is a reading, the magneto coils and/or thewiring from the coils is grounded and needs to bereplaced or repaired.DYNAMIC TESTDisconnect the magneto wiring harness connectorand probe the three connectors.1. Connect the test probes of the multimeter totwo of the YELLOW wires of the 3-pin magnetoharness adapter.2. Set multimeter to Vac scale.3. Start and rev engine to 3500 RPM. The obtainedvalue should be approximately 25 Vac.4. If the magneto is out of specification, replace it.BATTERYRecommendedExide RV24-130, 12 V, 25 A•h (130 minutes reserve)or equivalent, with top-mounted, roundtaper type battery posts.Battery maximum allowed size: 285 mm (11-1/4 in)long x 190 mm (7-1/2 in) wide x 238 mm (9-3/8 in)high.108-02-2 LMR2004-020-08-02A.FM

Section 08 ELECTRICAL SYSTEMSubsection 02 (CHARGING SYSTEM)TroubleshootingSYMPTOM: DISCHARGED OR WEAK BATTERYRemovalCAUSE1. Battery posts and/orcable terminaloxidized.2. Loose or badconnections.3. Faulty battery(sulfated, doesn’tkeep a full charge,damaged casing,loose post).4. 15 amp fuse(s) burntor faulty rectifier.5. Faulty batterycharging coil (orstator).REMEDYClean and coat withdielectric grease.Check wiring andconnector cleanliness,damaged or short circuit.Replace.First check fuse.If it is in good condition,check rectifier/regulator.Replace. WARNINGBattery BLACK negative cable must alwaysbe disconnected first and connected last.Never charge or boost battery while installedin sport boat.Proceed as follows:1. Disconnect the BLACK negative cable first.2. Disconnect the RED positive cable last.3. Remove the hold down.4. Withdraw battery from bilge. WARNINGElectrolyte is poisonous and dangerous.Avoid contact with eyes, skin and clothing.Wear a suitable pair of non-absorbent gloveswhen removing the battery by hand.CAUTION: Should any electrolyte spillage occur,immediately wash off with a solution ofbaking soda and water.CleaningClean the battery casing, caps, cables and batteryposts using a solution of baking soda and water.CAUTION: Do not allow cleaning solution toenter battery.Remove corrosion from battery cable terminalsand battery posts using a firm wire brush. Rinsewith clear water and dry well.InspectionVisually inspect battery casing for cracks or otherpossible damage. If casing is damaged, replacebattery and thoroughly clean battery tray and closearea with water and baking soda.Inspect battery posts for security of mounting.Inspect for cracked or damaged battery caps, replacedefective caps. WARNINGBattery electrolyte is caustic. To prevent spillage,battery cell cap should be sufficientlytight to properly seal.Electrolyte LevelCheck electrolyte level in each cell, add distilledwater to upper level as per battery manufacturer’sspecifications.CAUTION: Add only distilled water into an activatedbattery.Battery TestingThere are 2 types of battery tests: electrolyte readingand load test. An electrolyte reading is madeon a battery without discharging current. It is thesimplest and most commonly used. A loaded testgives more accuracy of the battery condition.Electrolyte ReadingCheck charge condition using either a hydrometeror multimeter.With a multimeter, voltage readings appear instantlyto show the state of charge. Always respectpolarity. A fully charge battery will have areading of 12.6 Vdc.LMR2004-020-08-02A.FM 08-02-3

Section 08 ELECTRICAL SYSTEMSubsection 02 (CHARGING SYSTEM)A hydrometer measures the charge of a battery interms of specific gravity of the electrolyte. A fullycharged battery will have a specific gravity between1.265 to 1.280.Most hydrometers only give a true reading at 21°C(70°F).1STATE OFCHARGESPECIFIC GRAVITY READINGUSING A HYDROMETERELECTROLYTETEMPERATURE27°C (80°F) 4°C (40°F)100% 1.26/1.27 1.27/1.2875% 1.21/1.22 1.22/1.2350% 1.16/1.17 1.17/1.1825% 1.12/1.13 1.13/1.140% 1.10 or less 1.11 or lessA17E0JA1. Specific gravity 1.265In order to obtain correct readings, adjust the initialreading by adding .004 points to the hydrometerreadings for each 5.5°C (10°F) above 21°C (70°F)and by subtracting .004 point for every 5.5°C(10°F) below 21°C (70°F).This chart will be useful to find the correct reading.ELECTROLYTETEMPERATURE°C °F3832271009080OPERATION TOPERFORM.012.008.004Addto thereading21 70 CORRECT READING16104- 160504030EXAMPLE NO. 1TEMPERATURE ABOVE 21°C(70°F):Hydrometer reading: 1.250Electrolyte temperature: - 1°C (30°F)Subtract .016 Sp. Gr.Corrected Sp. Gr. is 1.234.004.008.012.016Subtractfrom thereadingEXAMPLE NO. 2TEMPERATURE ABOVE 21°C(70°F):Hydrometer reading: 1.235Electrolyte temperature: 38°C (100°F)Add .012 Sp. Gr.Corrected Sp. Gr. is 1.247Load TestThis is the best test of battery condition under astarting load. Use a load testing device that has anadjustable load.Apply a load of 3 times the ampere-hour rating ofthe battery. At 14 seconds into the test, check batteryvoltage; if battery is in good condition, it willhave at least 10.5 Vdc.Battery StorageCAUTION: Battery storage is critical for batterylife. Regularly charging the battery during storagewill prevent cell sulfation. Keeping the batteryin vehicle for storage may lead to contactsdegradation/corrosion and case damage iffreezing occurs. A discharged battery willfreeze and break in area where freezing point isexperienced. Electrolyte leakage will damagesurrounding parts. Always remove batteryfrom vehicle for storage and regularly chargeto keep an optimal condition.Disconnect and remove battery from sport boat asexplained in REMOVAL.Check electrolyte level in each cell, add distilledwater up to upper level line.CAUTION: Do not overfill.The battery must always be stored in fully chargedcondition. If required, charge until specific gravityof 1.265 is obtained.CAUTION: Battery electrolyte temperature mustnot exceed 50°C (122°F). The casing should notfeel hot.08-02-4 LMR2004-020-08-02A.FM

Section 08 ELECTRICAL SYSTEMSubsection 02 (CHARGING SYSTEM)Clean battery terminals and cable connections usinga wire brush. Apply a light coat of dielectricgrease on terminals.Clean battery casing and caps using a solution ofbaking soda and water.CAUTION: Do not allow cleaning solution toenter battery.Rinse battery with clear water and dry well usinga clean cloth.Store battery in a cool dry place. Such conditionsreduce self-discharging and keep fluid evaporationto a minimum. Keep battery away from dew, highmoisture and direct sunlight.During the storage period, recheck electrolyte leveland specific gravity readings at least everymonth. If necessary, keep the battery at its upperlevel line and near full charge as possible (tricklecharge).Activation of a New Battery WARNINGNever charge or boost battery while installedin sport boat.Follow battery manufacturer’s recommendations.Charging a Used Battery WARNINGNever charge battery while installed in sportboat.For best results, battery should be charged whenthe electrolyte and the plates are at room temperature.A battery that is cold may not accept currentfor several hours after charging has begun.Do not charge a frozen battery. If the batterycharge is very low, the battery may freeze. If it issuspected to be frozen, keep it in a heated areafor about 2 hours before charging. WARNINGAlways charge battery in a well ventilated area.The time required to charge a battery will vary dependingon some factors such as:– Battery temperature: The charging time is increasedas the temperature goes down. A coldbattery accepts a lower rate of charging currentthan will a warm battery.– State of charge: Because the electrolyte is nearlypure water in a completely discharged battery,it cannot accept current as well as moreconcentrated electrolyte. This is the reason thebattery will not accept current when the chargingcycle first begins. As the battery remains onthe charger, the current from the charger causesthe electrolytic acid content to rise whichmakes the electrolyte a better conductor andthen, the battery will accept a higher chargingrate.– Type of charger: Battery chargers vary in theamount of voltage and current that they cansupply. Therefore, the time required for the batteryto begin accepting measurable current willalso vary.Charging a Weak or Completely DischargedBatteryThe battery charger should have an adjustablecharging rate. Variable adjustment is preferred,but a unit which can be adjusted in small incrementsis acceptable.The battery charger must be equipped with an ammetercapable of accurately measuring current ofless than 1 ampere.Unless this procedure is properly followed, a goodbattery may be needlessly replaced.– Measure the voltage at the battery posts withan accurate voltmeter. If it is below 10 volts, thebattery will accept current at a very low rate, interm of milliamperes, because the electrolyte isnearly pure water as explained above. It couldbe some time before the charging rate increases.Such low current flow may not be detectableon some charger ammeters and the batterywill seem not to accept any charge.– Except for this particular case, set the chargerto a high rate.LMR2004-020-08-02A.FM 08-02-5

Section 08 ELECTRICAL SYSTEMSubsection 02 (CHARGING SYSTEM)NOTE: Some chargers have a polarity protectionfeature which prevents charging unless the chargerleads are connected to the correct battery terminals.A completely discharged battery may not haveenough voltage to activate this circuitry, even thoughthe leads are connected properly. This will make itappear that the battery will not accept a charge. Followthe charger manufacturer’s instruction on howto bypass or override this circuitry so that the chargerwill turn on and charge a low-voltage battery.– Since the battery chargers vary in the amountof voltage and current they provide, the timerequired for the battery to accept measurablecharger current might be up to 10 hours ormore.– If the charging current is not up to a measurableamount at the end of about 10 hours, the batteryshould be replaced.– If the charging current is measurable before theend or at the end of about 10 hours, the batteryis good and charging should be completed inthe normal manner as specified in the manufacturer’srecommendations.– It is recommended that any battery rechargedby this procedure be load tested prior to returningit to service.Battery Installation WARNINGAlways connect battery cables exactly in thespecified order, RED positive cable first BLACKnegative cable last.Proceed as follows:1. Install battery in supplied tray.2. First connect RED positive cable. Tighten nuts.3. Connect BLACK negative cable last. Tighten nuts.4. Apply dielectric grease on battery posts.5. Verify cable routing and attachment.08-02-6 LMR2004-020-08-02A.FM

Section 08 ELECTRICAL SYSTEMSubsection 03 (STARTING SYSTEM)STARTING SYSTEM 0Grease Klueber IsoflexTopas NB 5243 251The solenoid may be the cause of a burnt fuse. Ifthe solenoid checks good, an accessory may bedefective.BatteryTo check battery condition, refer to CHARGINGSYSTEM.VCM/ECMIf 2 short beeps are not heard when installing thesafety lanyard, refer to ENGINE MANAGEMENTsection.Engine Start/Stop Switch and SafetyLanyard SwitchRefer to ENGINE MANAGEMENT section.F18H0MANOTE: This procedure to be performed for eachengine.GENERALCauses of trouble are not necessarily related tostarter but may be due to a burnt fuse, faulty battery,start/stop switch, safety lanyard switch, engine fuseblock or ECM, solenoid, electrical cables, connections,hydrolock or engine mechanical failure.Check these components before removing starter.Consult the starting system troubleshooting tableon page 2 for a general view of possible problems. WARNINGShort circuiting electric starter is always adanger, therefore disconnect the batteryground cable before performing any kind ofmaintenance on starting system. Do not placetools on battery.FuseMake sure the starting system fuse on enginefuse block is in good condition.SolenoidNOTE: Solenoid is located near the fuse block for4-TEC engines.Inspect connections and clean as necessary.Static Test: ContinuityWith a multimeter, check primary winding resistance.It should be approximately 5.0 Ω (ohms).Measure the resistance value through pins 1 and 2.F04H71A1. Pins 1 and 2There should be no continuity between the positiveposts of the solenoid.1LMR2004_021_08_03A.FM 08-03-1

Section 08 ELECTRICAL SYSTEMSubsection 03 (STARTING SYSTEM)Dynamic TestDepress start/stop button and measure the voltageon the solenoid positive posts with a multimeter.If there is no voltage and battery is in good condition,replace the solenoid.Electrical Cables or ConnectionsCheck all connections, cables and wires. Tightenany loose cables. Replace any chafed wires.STARTING SYSTEM TROUBLESHOOTINGNOTE: Other causes of the problem may not be related to the starting system. Refer to TROUBLESHOOT-ING section.SYMPTOM CAUSE REMEDYSTARTER DOES NOT TURN. Burnt fuse on engine fuse block. Check wiring condition and replacefuse.Poor contact of battery terminal(s). Clean and tighten terminal(s).Poor battery ground cable connection. Clean and tighten.Weak battery.Recharge or replace battery.STARTER ENGAGES;BUT DOES NOT CRANKTHE ENGINE.STARTER TURNS, BUTOVERRUNNING CLUTCHPINION DOES NOT MESHWITH RING GEAR.STARTER MOTOR KEEPSRUNNING.Poor contact of start/stop switch,safety lanyard switch or solenoid.Open circuit: start/stop switch orsolenoid.Safety lanyard.Engine hydrolocked.Poor battery cable connections.Poor contact of brushes.Burnt commutator.Worn commutator segments.Shorted armature.Weak brush spring tension.Weak magnet.Worn bushings.Weak battery.Worn clutch pinion gear.Defective clutch.Poor movement of clutch on splines.Worn clutch bushing.Worn ring gear.Shorted solenoid winding.Melted solenoid contacts.Sticking or defective starter clutch.Check connectors and clean contacts.Check and replace defective parts.Check and replace.Refer to ENGINE MANAGEMENT.Refer to MAINTENANCE.Clean battery cable connections.Straighten commutator and brushes.Turn commutator on a lathe.Undercut mica.Repair or replace armature.Replace brush holder or spring.Replace yoke assembly.Replace clutch.Recharge or replace battery.Replace clutch.Replace clutch.Clean and correct.Replace clutch.Replace ring gear.Replace solenoid.Replace solenoid.Lubricate or replace.08-03-2 LMR2004_021_08_03A.FM

Section 08 ELECTRICAL SYSTEMSubsection 03 (STARTING SYSTEM)STARTER REMOVALDisconnect BLACK cable ground connection frombattery. WARNINGAlways disconnect ground cable first and reconnectlast.Disconnect RED cable connection from battery.Remove retaining screws no. 1 from starter.Pull starter no. 3 out. Lift starter enough to reachstarter cable then disconnect from starter (nutno. 2).421F18H0NA 1 21. Starter gear2. Retaining circlipLocate index marks on yoke and end covers.3F18H0UA1. Exhaust manifold2. Starter3. Retaining screws4. NutSTARTER DISASSEMBLYRemove gear retaining circlip no. 4 and startergear no. 5.F18H0OA1. Index marks1LMR2004_021_08_03A.FM 08-03-3

Section 08 ELECTRICAL SYSTEMSubsection 03 (STARTING SYSTEM)Loosen through bolts.1F06H1JA 1TYPICAL1. Pull armature shaftRemove brushes from brush holder by looseningretaining screws.12 3F18H0PA1. Through boltsRemove end cover.Remove thrust washers from armature shaft.F18H0QAF06H1HA 1TYPICAL1. Thrust washersRemove the other end cover containing brushes andbrush holder assembly.Remove armature.1. Brushes2. Retaining screw3. Brush holderRemove springs.CLEANINGCAUTION: Yoke ass’y and drive unit assemblymust not be immersed in cleaning solvent.Discard all O-rings.Clean brushes and holders with a clean cloth soakedin solvent. Brushes must be dried thoroughly with aclean cloth.08-03-4 LMR2004_021_08_03A.FM

Section 08 ELECTRICAL SYSTEMSubsection 03 (STARTING SYSTEM)Blow brush holders clean using compressed air. WARNINGAlways wear safety glasses when using compressedair.Remove dirt, oil or grease from commutator usinga clean cloth soaked in a suitable solvent. Dry wellusing a clean, dry cloth.Clean engine ring gear teeth and drive unit (clutch).NOTE: Bushings or bearings must not be cleanedwith grease dissolving agents.Immerse all metal components in cleaning solution.Dry using a clean, dry cloth.PARTS INSPECTIONArmatureNOTE: An ohmmeter may be used for the followingtesting procedures, except for the one concerningshorted windings in armature.Check commutator for rough, burnt or scored surface.If necessary, turn commutator on a lathe,enough to resurface only.Check commutator for mica depth. If depth is lessthan 0.20 mm (.008 in), undercut mica. Be surethat no burrs are left and no copper dust remainsbetween segments after undercutting operationis completed.Check commutator condition with an indicator. Ifout of specification, replace the starter.1Brush HolderCheck brush holder for insulation using an ohmmeter.Place one test probe on insulated brushholder and the other test probe on brush holderplate. If continuity is found, brush holder has to berepaired or replaced.BrushMeasure brush length. If less than 8.5 mm (.335 in),replace them.NOTE: New brush length is 12 mm (.472 in).A03E05A1 2TYPICAL1. New2. Wear limit, 8.5 mm (.335 in)Overrunning ClutchPinion of overrunning clutch should turn smoothlyin clockwise direction, and should not slip in acounterclockwise direction. If defective, replace.Check pinion teeth for wear and damage. If defective,replace.NOTE: Always check engine ring gear teeth forwear and damage. If defective replace ring gear.Refer to MAGNETO.STARTER ASSEMBLYReverse the order of disassembly to reassemblestarter. However, attention should be paid to thefollowing operations.Install new O-rings.F18H0RA1. Commutator undercut 0.20 mm (.008 in)LMR2004_021_08_03A.FM 08-03-5

Section 08 ELECTRICAL SYSTEMSubsection 03 (STARTING SYSTEM)Insert thrust washer onto armature shaft.NutCAUTION: Use ONLY a 1/4-20 UNC stainless nuton starter cable stud.Connect the RED positive cable to the starter andtorque nut to 7 N•m (62 lbf•in). Apply dielectricgrease on terminal and nut.Slide protective boot over nut to shield metallic partsfrom potential electrical shorting and corrosion.F06H1HA 11. Thrust washerWhen installing end covers to yoke, align index marks.Apply Loctite 271 (red) on through bolts and torqueto 6 N•m (53 lbf•in).STARTER INSTALLATIONInstallation is essentially the reverse of removalprocedure. However, pay particular attention to thefollowing.Make sure that starter and engine mating surfacesare free of debris. Serious trouble may arise if starteris not properly aligned.Apply grease Isoflex Topas NB52 (P/N 293 550 021)on O-rings of starter.Install Starter.NOTE: If starter does not mesh properly, try to pullit out and slightly rotate the starter gear; then reinstallstarter. If necessary, temporarily remove bothO-rings, properly mesh gears then remove starterto reinstall O-rings, being careful not to rotate gearto keep its position, to finally reinstall starter.Apply Loctite 243 (blue) on retaining screws no. 1and torque to 10 N•m (89 lb•in).F18H0UB2 311. Grease on O-rings2. Torque nut to 7 N•m (62 lbf•in) and apply dielectric grease andinstall protection cover3. Apply Loctite 243 to threads and torque screws to 10 N•m(89 lbf•in) WARNINGAlways connect RED positive cable first thenBLACK negative cable last. Whenever connectingthe RED positive cable to the startermotor make sure the battery cables are disconnectedto prevent electric shock.08-03-6 LMR2004_021_08_03A.FM

Section 08 ELECTRICAL SYSTEMSubsection 03 (STARTING SYSTEM)STARTER SPECIFICATIONNominal outputVoltageRated timeRotationWeightPerformance specification at 20°C (68°F)Battery0.9 kW12 V30 secondsCounterclockwise (viewed from pinion side)2.5 kg (5.39 lb)No load 11.4 V 23 A max. 8600 RPMLoad 8.5 V 140 A max. 5200 RPMStall 3.75 V 330 A max. 0 RPM12 V, 30 AhLMR2004_021_08_03A.FM 08-03-7

Subsection 04Section 08 ELECTRICAL SYSTEM(INSTRUMENTS AND ACCESSORIES)INSTRUMENTS AND ACCESSORIES 0ADDITION OF ACCESSORIESEvery time an accessory is added, it must be registeredusing B.U.D.S. to activate it in the MPEM.If an option is checked in B.U.D.S. but not installedin vehicle, a fault code will be generated.Use the OPTIONS area in the Setting tab in B.U.D.S.INSPECTIONSpeed SensorThe speedometer gives a reading through a speedsensor. Speed sensor is installed on the hull. Waterpassing under the hull turns a magnetic paddlewheel that triggers an electronic pick-up that inturn sends a speed signal to the speedometer.The paddle wheel is protected by the pick-uphousing.Install safety lanyard to activate system.Slowly rotate the paddle wheel. Every 1/8 turn, theobserved voltage should fluctuate between 5.5and 8.5 Vdc.Fuel Gauge and Sender CheckEnsure accessory fuse is good and gauge is gettingpower (PURPLE wire) and a proper ground (BLACKwire).Fuel Gauge VerificationEnsure battery is charged and battery switch is on.Remove rear seat cushions.F13F06A11 21. Remove these cushionsRemove rear seat storage tubs.F13H08A1. Pick-up housing2. Paddle wheelTo check if the speed sensor is operational, disconnectthe speed sensor connector housing from insidebilge.Using an appropriate terminal remover (Snap-onTT600-4), remove the PURPLE/YELLOW andBLACK/ORANGE wires from the tab housing ofthe speed sensor.Reconnect the PURPLE/YELLOW and BLACK/ORANGE wires in the receptacle housing.Connect the positive probe of a multimeter tospeed sensor PURPLE/YELLOW wire and the negativeprobe to speed sensor BLACK/ORANGE wire.F13F05A1. Remove these storage tubsInstall lanyard on DESS post.1LMR2004-022-08-04A.FM 08-04-1

Section 08 ELECTRICAL SYSTEMSubsection 04 (INSTRUMENTS AND ACCESSORIES)Unplug the two-wire connector (PINK and PINK/BLACK wires) near fuel pump module.F13F07AUNPLUG THIS CONNECTORMomentarily short the PINK and PINK/BLACK wiresof the harness together using a jumper wire. Withouta jumper the gauge should read empty. Whenthe wires are jumped the gauge should read full.RESISTANCE(Ω)Fuel Baffle Pick-Up SenderWET HEIGHT FROMBOTTOM (mm)4.8 ± 2.2 247 ± 5.017.8 ± 2.2 207 ± 5.027.8 ± 2.2 183 ± 5.037.8 ± 2.2 158 ± 5.047.8 ± 2.2 133 ± 5.057.8 ± 2.4 105 ± 5.067.8 ± 2.8 76 ± 5.077.8 ± 3.6 55 ± 5.089.8 ± 3.6 35.3 ± 5.0The fuel pick-up system is part of the fuel pumpmodule mounted inside the fuel reservoir.The fuel level gauge sender is also mounted onthis module.1F13F08A1. Jump PINK and PINK/BLACK wiresIf the gauge needle does not move when the wiresare jumped, check the harness connections at thegauge or replace gauge.If the gauge needle moves to “FULL” when thewires are jumped, the gauge is working correctly.If the sending unit is suspect, connect an Ohmmeter to the PINK and PINK/BLACK wires of thefuel module (NOT the harness) and note the reading.The resistance reading should be somewherebetween 2.6 and 93 ohms (see following chart).F07F09ATYPICAL — FUEL LEVEL GAUGE SENDER MOUNTED ON FUELPUMP MODULERefer to ENGINE MANAGEMENT.08-04-2 LMR2004-022-08-04A.FM

Section 09 PROPULSION SYSTEMSubsection 01 (TABLE OF CONTENTS)TABLE OF CONTENTS 0JET PUMP .............................................................................................................................. 09-02-1GENERAL ........................................................................................................................... 09-02-2JET PUMP INSPECTION ON SPORT BOAT..................................................................... 09-02-2REMOVAL........................................................................................................................... 09-02-3DISASSEMBLY................................................................................................................... 09-02-4CLEANING ......................................................................................................................... 09-02-7PARTS INSPECTION.......................................................................................................... 09-02-8ASSEMBLY......................................................................................................................... 09-02-9PUMP PRESSURIZATION ................................................................................................. 09-02-13INSTALLATION .................................................................................................................. 09-02-13DRIVE SYSTEM ..................................................................................................................... 09-03-1GENERAL ........................................................................................................................... 09-03-2REMOVAL........................................................................................................................... 09-03-2INSPECTION ...................................................................................................................... 09-03-5INSTALLATION .................................................................................................................. 09-03-6LMR2004-030_09_01ATOC.FM 09-01-1

Section 09 PROPULSION SYSTEMSubsection 02 (JET PUMP)JET PUMP 034 35366 N•m(53 lbf•in)44Loctite518303233Primer N and 45Loctite 24340 412531 N•m(23 lbf•ft)46 Alsacogrease28Loctite45437137.5 N•m(66 lbf•in)263 21Pipe sealant59242243124 N•m(18 lbf•ft)212322839 43Loctite 24321 N•m(15 lbf•ft)2048F04J4FSLMR2004-023-09-02A.FM 09-02-1

Section 09 PROPULSION SYSTEMSubsection 02 (JET PUMP) WARNINGScrews must be torqued as specified.NOTE: These procedures to be performed oneach engine.GENERAL143521F02J0VA1. Stamped part numberF00J0SATYPICAL1. Nozzle2. Venturi3. Housing4. Wear ring5. Impeller6. StatorDisassembly PreparationHands, tools, bench, rags must be clean beforepump disassembly.CAUTION: Pump grease tube must be openedat the very last moment to avoid contamination.Impeller Identification6To identify the impellers refer to the following illustrationand chart.SPORT BOATMODELSIMPELLERP/N5773/5160 271 001 386JET PUMP INSPECTION ONSPORT BOATTo work on sport boat, securely install it on a stand.Thus, if access is needed to water inlet area, it willbe easy to slide underneath sport boat.Impeller ConditionMATERIALStainlesssteelPITCHProgressivepitch13° - 23°Condition of impeller no. 1, boot no. 2 and ringno. 3 can be quickly checked from underneath ofthe sport boat. Remove grate and look throughwater inlet opening.1F01J0DATYPICAL1. Inspect impeller and boot09-02-2 LMR2004-023-09-02A.FM

Section 09 PROPULSION SYSTEMSubsection 02 (JET PUMP)Impeller/Wear Ring ClearanceThis clearance is critical for jet pump performance.Clearance can be checked from water inlet openingor from venturi side. However, the last methodrequires more work.To check clearance from water inlet side, removeinlet grate.To check clearance from venturi side, remove venturi/nozzle assembly.Using a feeler gauge with 30 cm (12 in) blades,measure clearance between impeller blade tip andwear ring. Measure each blade at its center. Clearanceshould not exceed 0.35 mm (.014 in). If clearanceis greater, disassemble jet pump and inspectimpeller and wear ring. Renew worn parts.1REMOVALPump AssemblyF13J01A 121. Reverse cable2. Steering cableDisconnect steering and reverse cables.Remove 4 pump retaining nuts no. 25.Pull out pump.Reverse GateTo remove reverse gate no. 4, put shift lever inreverse position.Remove reverse cable.F01J0EATYPICAL — MEASURING FROM WATER INLET SIDE1. Feeler gaugeF04J4CA11. Screw no. 8 (portside)Remove both reverse gate screws no. 8.F01J0FA 1TYPICAL — MEASURING FROM VENTURI SIDE1. Feeler gaugeLMR2004-023-09-02A.FM 09-02-3

Section 09 PROPULSION SYSTEMSubsection 02 (JET PUMP)NozzleRemove reverse gate.Disconnect steering cable from jet pump nozzle.Remove 2 retaining screws no. 21, 2 sleeves no. 22,2 washers no. 23.Remove nozzle.VenturiRemove:– reverse gate– nozzle.Remove 4 retaining screws no. 39 and withdrawventuri no. 24.It’s possible to remove the venturi without removingthe reverse gate and the nozzle, see the followinginstructions.Disconnect:– steering cable– reverse cable.F13J01A 121. Reverse cable2. Steering cableRemove 4 retaining screws no. 39 and withdrawventuri no. 24.F02J0TATYPICAL1. Remove screwsJet Pump HousingRemove pump as an assembly or remove the following:– nozzle– venturi.Loosen 4 hexagonal nuts no. 25 and remove flatwashers no. 40 and lock washers no. 41 from jetpump housing.Remove jet pump with a wiggle movement.CAUTION: When removing pump unit, a shimcould have been installed between hull andpump housing. Be sure to reinstall it otherwiseengine and jet pump alignment will be altered.NOTE: After jet pump removal, if drive shaft remainsin the PTO flywheel, simply pull it out. Ifdrive shaft is seized in the PTO flywheel, refer toDRIVE SYSTEM.DISASSEMBLY11NOTE: Whenever removing a part, visually checkfor damage such as: corrosion, crack, split, break,porosity, cavitation, deformation, distortion, heatdiscoloration, wear pattern, missing plating, missingor broken balls in ball bearing, water damagediagnosed by black-colored spots on metal parts,etc. Renew any damaged part. As a quick check,manually feel clearance and end play, where applicable,to detect excessive wear.09-02-4 LMR2004-023-09-02A.FM

Section 09 PROPULSION SYSTEMSubsection 02 (JET PUMP)CoverWith pump housing in vertical position, remove 3retaining screws no. 26.F18J0NAF18J0LAUsing a fiber hammer, gently tap cover to releaseit from jet pump housing. Use flat screwdriver toremove cap.F18J0OAImpellerRemove ring no. 3, impeller boot no. 2. Replacethem if damaged.Mount impeller remover/installer (P/N 529 035 820)in a vise.F18J0MA529 035 820Check for presence of water in cone and bearing.If so, replace oil seal no. 35 and sleeve no. 30.Remove both O-rings no. 37 and circlip no. 45.F18J0PALMR2004-023-09-02A.FM 09-02-5

Section 09 PROPULSION SYSTEMSubsection 02 (JET PUMP)Install pump over this tool.F18J0SAF18J0QARemove shield no. 34.Using a 12 mm Allen key, unscrew the impeller.NOTE: It may be necessary to heat the impeller inorder to break Loctite bond.F18J0TAF18J0RACAUTION: Never use an impact wrench to loosenthe impeller.To remove the impeller, rotate and pull at the sametime. Slide impeller out of housing.Remove pump housing.Use the impeller shaft pusher (P/N 529 035 818)to press impeller shaft no. 28 out of pump housing.Bearing no. 33, shaft sleeve no. 30, O-ringno. 46 and spacer no. 32 will come out with theimpeller shaft.529 035 818F18J0UA09-02-6 LMR2004-023-09-02A.FM

Section 09 PROPULSION SYSTEMSubsection 02 (JET PUMP)CAUTION: Bearing inner race being in 2 parts,bearing may fall apart during removal.Use the seal/bearing pusher (P/N 529 035 819) topress out bearing no. 33 from impeller shaft.After cutting ring, insert a screwdriver blade betweenjet pump housing and ring outside diameter.Push ring so that it can collapse internally.Pull ring out.CLEANINGThoroughly clean jet pump housing by applying LoctiteStripper (P/N 293 110 004). Allow it some timeto dissolve the old dried Loctite (10 to 15 minutes). WARNINGTechnician should wear gloves when using thiscleaning product.F18J0VA529 035 819From the outlet side of pump, use the seal/bearingpusher (P/N 529 035 819) to press out the oil sealno. 35.529 035 819CAUTION: DO NOT use Loctite Stripper on wearring since it will cause irreparable damage to it.Remove Loctite Stripper from surface with a cleancloth.Make sure surface is cleaned and dried of LoctiteStripper.Sealant on the jet pump housing can be removedwith a wire brush (disc) mounted on a drill or ascraper.Properly clean all threads.Remove all O-rings and clean parts in a solvent.Carefully check water passages. Blow low pressurecompressed air through them and make surethey are clear.1F18J0WARemove large O-ring no. 36 from pump housing.Wear RingRemove the screws retaining wear ring in the jetpump housing.Place jet pump housing in a vise with soft jaws. Itis best to clamp housing using a lower ear.Cut wear ring at two places.CAUTION: When cutting ring, be careful not todamage jet pump housing.NOTE: Wear ring can be cut using a jigsaw, a smallgrinder or a low clearance hacksaw such as Snap-onHS3 or equivalent.F18J0XA1. Water passagesBrush and clean impeller shaft threads, impellerand drive shaft splines with pulley flange cleaner(P/N 413 711 809) or equivalent. Free threads andsplines from any residue.LMR2004-023-09-02A.FM 09-02-7

Section 09 PROPULSION SYSTEMSubsection 02 (JET PUMP)PARTS INSPECTIONImpellerVisually inspect impeller splines. Check for wearor deformation. Renew parts if damaged.NOTE: Check also PTO flywheel and drive shaft condition.Refer to BOTTOM END and DRIVE SYSTEM.Examine impeller in wear ring for distortion.Check if blade tips are blunted round, chipped orbroken. Such impeller is unbalanced and will vibrateand damage wear ring, impeller shaft, shaftseal or bearings. Renew if damaged.F18J1BA1. Replace if blunted round or damaged1Check impeller for cavitation damage, deep scratchesor any other damage.Wear RingCheck wear ring no. 31 for deep scratches, irregularsurface or any apparent damage.If impeller/wear ring clearance is too large and impelleris in good shape, renew wear ring.Ball Bearing and Impeller ShaftWEARIMPORTANT: Make sure to reassemble ball cage,bearing inner and outer races to their original position.Inspect ball bearing no. 33. Check for corrosion,scoring, pitting, chipping or other evidence of wear.With your finger nail, feel contact surface of sleeve.If any irregular surface is found, renew sleeveno. 30 and seal.Install bearing, then install impeller shaft and rotateit. Make sure it turns smoothly.RADIAL PLAYRadial play is critical for jet pump unit life span.Radial play of impeller shaft is checked with shaftin housing, with impeller.Retain housing in a soft jaw vise making sure notto damage housing lug.Set a dial gauge and position its tip onto metal end,close to end of threads.Move shaft end up and down. Difference betweenhighest and lowest dial gauge reading is radial play.Maximum permissible radial play is 0.75 mm (.029 in).1F18J1DA 1 2F18J1CAMEASURING IMPELLER SHAFT RADIAL PLAY1. Dial gauge2. Measure close to threads at shaft end1. Check for cavitation, deep scratches or other damage09-02-8 LMR2004-023-09-02A.FM

Section 09 PROPULSION SYSTEMSubsection 02 (JET PUMP)Excessive play can come either from worn bearingor damaged jet pump housing bearing surface.SealCarefully inspect seal lips. Make sure that lips arenot worn, distorted, cracked or show signs of anyother damage. Replace after 100 hours.BearingReplace bearing whenever the marks of corrosionand presence of water is found.ASSEMBLYHands, tools, bench, rags must be clean beforepump assembly.CAUTION: Pump grease tube must be openedat very last moment to avoid contamination.Wear RingThis model is equipped with a large pump. It is importantthat the screws retaining wear ring to housingare installed on this model.F08J07ATo install ring in housing, use a square steel plateof approximately 180 x 180 mm x 6 mm thick (7 x7 in x 1/4 in) and a press.Manually engage ring in housing making sure it isequally inserted all around. Press ring until it seatsinto bottom of housing.12F01J5DAF08J06A1. Seal lip2. Press wear ringIf a press is not readily available, a piece of woodsuch as a 2 x 4 in x 12 in long, can be used.LMR2004-023-09-02A.FM 09-02-9

Section 09 PROPULSION SYSTEMSubsection 02 (JET PUMP)Manually engage ring in housing making sure it isequally inserted all around. Place wood piece overring. Using a hammer, strike on wood to push ring.Strike one side then rotate wood piece about 90°and strike again. Frequently rotate wood piece sothat ring slides in evenly until it seats into bottomof housing.529 035 819123F18J0YAInstall spacer no. 32 on shaft no. 28.Install O-ring no. 46 in sleeve no. 30.1F01J5EA1. Piece of wood2. Seal lip facing upward3. Wear ringNOTE: Do not forget, install two retaining screwson top of the large pump models.BearingUsing the seal/bearing pusher (P/N 529 035 819)press the bearing no. 33 by its inner race on theimpeller shaft no. 28.Be careful when removing the plastic retainer fromthe bearing no. 33 to avoid the inner races fromfalling apart. Make sure to reassemble bearingparts to their original position.The bearing no. 33 can be installed either side.F18J0ZA1. O-ringCoat shaft surface with jet pump bearing grease(P/N 293 550 032) then, install sleeve no. 30 onimpeller shaft no. 28.F18J10A09-02-10 LMR2004-023-09-02A.FM

Section 09 PROPULSION SYSTEMSubsection 02 (JET PUMP)From the outlet side of pump, press impeller shaftassembly into housing using shaft pusher (P/N 529035 818).1529 035 818F18J13A1. Lips facing up529 035 819F18J11AInstall circlip no. 45 and O-rings no. 37.Apply 10 cc of jet pump bearing grease (P/N 293550 032) on bearing.F18J14AF18J12APress oil seal no. 35 using seal/bearing pusher(P/N 529 035 819) until tool bottoms. Make sureseal lips are facing up.On the outlet side, install 2 O-rings no. 37 in theirrespective groove.Before installing any other parts, pump can bepressurized to insure proper seal installation. SeePUMP PRESSURIZATION below.On the impeller side, install shield no. 34.LMR2004-023-09-02A.FM 09-02-11

Section 09 PROPULSION SYSTEMSubsection 02 (JET PUMP)Apply Loctite 243 on impeller shaft and impellerthreads.Apply 50 cc of jet pump bearing grease (P/N 293550 032) in the impeller shaft area.F18J15AF18J17AApply another 50 cc of jet pump bearing grease(P/N 293 550 032) in the impeller cover.F18J16AApply BOMBARDIER LUBE on the wear ring surface.Start screwing the impeller on its shaft. Ifimpeller is too tight, use impeller tool to turn impellerto machine wear ring before installing on vehicle.Make sure to turn it smooth enough so thatengine starter should turn it.Mount impeller remover/installer (P/N 529 035 820)in a vise.Install partially screwed impeller on it.Use a 12 mm Allen key to torque impeller shaft to125 N•m (92 lbf•ft) then remove tool.CAUTION: Never use any impact wrench to tightenimpeller shaft.F18J18AInstall impeller cover with new self-locking screws.Torque to 7 N•m (62 lbf•in).VenturiPosition venturi no. 24 with bailer passages on top.Apply Loctite 243 (blue) on threads of screws no. 39.Install screws no. 39, lock washers and flat washersthen torque to 21 N•m (15 lbf•ft).09-02-12 LMR2004-023-09-02A.FM

Section 09 PROPULSION SYSTEMSubsection 02 (JET PUMP)F02J0TA1. Torque screws to 21 N•m (15 lbf•ft)PUMP PRESSURIZATION11Whenever doing any type of repair on jet pump, apressure test should be done to check for leakage.Proceed as follows:– Remove impeller cover no. 13. Install pressurecap (P/N 529 035 843) on pump housing.– Connect pump gauge tester (P/N 529 021 800)to fitting.– Pressurize pump to a maximum of 70 kPa (10 PSI).NOTE: If there is a pressure drop spray soapy wateraround cover. If there are no bubbles, impellershaft, impeller shaft seal, or jet pump housing isleaking through porosity and has to be replaced.Jet pump unit has to be disassembled. There maybe 2 or 3 bubbles coming out from sleeve no. 30seal area. This small leak is acceptable. Leaks fromother areas must be repaired.– Disconnect pump gauge tester and remove pressurecap.– Reinstall impeller cover no. 13 with 3 new selflockingscrews.INSTALLATIONJet Pump HousingMake sure that black rubber covered reducerno. 44 is installed as shown.CAUTION: Misinstallation can cause overheatingand damage to exhaust system.1529 035 843F18J0IAF18J19A– Pump must maintain this pressure for at least 5minutes.CAUTION: Repair any leak, failure to correct aleak will lead to premature wear of pump components.1. Black rubber covered reducerGenerously apply synthetic grease on drive shaftsplines.Make sure rubber damper is on drive shaft PTO end.Install jet pump. If necessary, wiggle jet pump toengage drive shaft splines in impeller.CAUTION: Some boats require a shim betweenhull and pump; if shim has been removed atpump removal, be sure to reinstall it, otherwiseengine alignment will be altered.Apply Loctite 243 (blue) on stud threads of jet pumphousing.Install flat washers no. 40, lock washers no. 41and nuts no. 25. Tighten nuts of jet pump housingin a criss-cross sequence and torque to 31 N•m(23 lbf•ft).LMR2004-023-09-02A.FM 09-02-13

Section 09 PROPULSION SYSTEMSubsection 02 (JET PUMP)NOTE: Slightly lubricate wear ring with BOMBARDIERLUBE lubricant to minimize friction during initial start.NozzleInsert bushing no. 42 in nozzle no. 20.Insert bushing no. 43 in nozzle no. 20 with its offsetpointing forward.Position their flanges from inside of nozzle.Insert sleeves no. 22 in bushings no. 42 and no. 43.Install nozzle on venturi no. 24; position its steeringarm on RH side. Apply Loctite 243 (blue) onscrew threads (or use new self-locking screws). Installscrews no. 21 and washer no. 23 then torqueto 24 N•m (18 lbf•ft). WARNINGScrews must be torqued as specified.Reverse GateInstall reverse gate with spacer and washer. Torqueto 20 N•m (177 lbf•in).Steering CableRefer to section, STEERING SYSTEM.1Reverse CableRefer to STEERING SYSTEM (THROTTLE/SHIFTERCONTROLLER).F04J4EA1. Bushing offset09-02-14 LMR2004-023-09-02A.FM

Section 09 PROPULSION SYSTEMSubsection 03 (DRIVE SYSTEM)DRIVE SYSTEM4-TEC Models5678910Loctiteantiseizelubricant11151216SyntheticgreaseF18I01SLMR2004-024_09_03A.FM 09-03-1

Section 09 PROPULSION SYSTEMSubsection 03 (DRIVE SYSTEM)GENERALNOTE: These procedures to be performed oneach engine.Jet pump must be removed to replace any componentsof the drive system. Refer to JET PUMPfor removal procedure.REMOVALNOTE: When drive shaft is removed, some oil willflow out. To prevent this, start engine, run at 4000RPM for 10 seconds and stop engine at this RPM.This will move oil out of PTO housing into oil tank.Floating Ring and PTO SealCAUTION: Strictly follow this procedure otherwisedamage to component(s) might occur. Liftsplash guard to expose PTO seal assembly. InstallPTO seal support tool (P/N 529 035 842) onbottom of PTO seal assembly as shown.1F18I04A1. Insert in groove of PTO seal assembly1Remove jet pump. Refer to JET PUMP section.Install drive shaft holder (P/N 529 035 871) onpump support as shown.NOTE: This is necessary so the drive shaft cannotmove rearwards when using the drive shaft/floatingring tool.F18B01A1. PTO seal support tool1F18B02A1. Drive shaft holder09-03-2 LMR2004-024_09_03A.FM

Section 09 PROPULSION SYSTEMSubsection 03 (DRIVE SYSTEM)21F18B03ATYPICALInstall drive shaft/floating ring tool (P/N 529 035841) as shown.F18I05AF18B04ADRIVE SHAFT/FLOATING RING TOOL1. Largest opening here2. Floating ringTurn screw clockwise so that the tool pushes thefloating ring rearwards to expose the C-clip. Donot remove clip at this time.NOTE: This step is done to ensure floating ring isfree and not stuck on the drive shaft.Remove drive shaft/floating ring tool and driveshaft holder.LMR2004-024_09_03A.FM 09-03-3

Section 09 PROPULSION SYSTEMSubsection 03 (DRIVE SYSTEM)Reinstall drive shaft/floating ring tool as shown.1F18B03A2TYPICALReinstall drive shaft/floating ring tool as shown.Push floating ring rearwards to expose C-clip andremove it.21F18I08A1. Largest opening here2. Lubricate both O-ringsTurn screw clockwise so that the tool pushes thePTO seal forward and the drive shaft to the rearto expose both O-rings. Lubricate O-rings withBOMBARDIER LUBE (P/N 293 600 016).NOTE: This is necessary to ease drive shaft removallater.Remove drive shaft/floating ring tool and PTO sealsupport.F18I0BA1. Largest opening here2. Remove C-clipRemove drive shaft holder tool then drive shaft/floating ring tool.NOTE: Use this sequence to minimize theamount of movement the drive will slide back intoPTO seal assembly.Drive ShaftSimply pull out drive shaft.09-03-4 LMR2004-024_09_03A.FM

Section 09 PROPULSION SYSTEMSubsection 03 (DRIVE SYSTEM)Place rags under PTO housing to prevent spillage.If spillage occurs, clean immediately with the pulleyflange cleaner (P/N 413 711 809) to prevent oilstains.NOTE: It may require a slight jerk to the rear toremove the O-rings from the PTO seal assembly.BootLoosen gear clamp no. 11 holding boot, then carefullypull boot and carbon ring no. 8 from hull insert.Carbon RingLoosen gear clamp no. 9 then pull carbon ringfrom boot no. 10.INSPECTIONDrive ShaftInspect condition of drive shaft and PTO flywheelsplines.Inspect condition of groove.With your finger nail, feel machined surface ofdrive shaft. If any irregular surface is found, renewdrive shaft.F01J15AMEASURING DRIVE SHAFT DEFLECTION1. Dial gauge2. V-blocksDamperDiscard damper and install a new one.Floating Ring and O-RingInspect condition of O-rings no. 7 and floating ringno. 6 contact surface.112F01I0FA 1 23TYPICAL1. Surface condition2. Groove condition3. Splines conditionDiscard both O-rings no. 16 and install new ones.Excessive deflection could cause vibration anddamage to drive shaft splines, impeller, flywheelor floating ring (seal carrier depending upon themodel).Place drive shaft on V-blocks and set-up a dialgauge in center of shaft. Slowly rotate shaft; differencebetween highest and lowest dial gaugereading is deflection. Refer to the following illustration.Maximum permissible deflection is 0.5 mm(.020 in).2F01I0GA1. O-rings2. Floating ring contact surfaceBootInspect the condition of boot. If there is any damageor evidence of wear, replace it.To verify the preload of the boot no. 10, proceedas follows:NOTE: To verify the boot preload and free length,jet pump and drive shaft must be installed.LMR2004-024_09_03A.FM 09-03-5

Section 09 PROPULSION SYSTEMSubsection 03 (DRIVE SYSTEM)Measure boot length when normally installed ondrive shaft. Ensure circlip no. 5 is properly installedinto groove.1INSTALLATIONInstallation is essentially the reverse of removalprocedure. However, pay particular attention tothe following.Drive Shaft and DampersEnsure to install a new damper no. 15 and newO-rings no. 16 on drive shaft no. 12.NOTE: Ensure to install floating ring before insertingthe drive shaft on PTO seal assembly.Before installing drive shaft, inspect PTO seal assembly.The inner sleeve must be flush with outercircumference of the assembly. Otherwise, gentlypush or tap on inner sleeve until flush.AF04J4AATYPICAL1. BootA. Measure hereThe measured distance of dimension “A” shouldbe between 63 mm (2.48 in) and 71 mm (2.80 in).If the length is more than 71 mm (2.80 in), installa spacer (P/N 293 250 017) between boot and thruhull fitting.1F18I0EA 1CORRECT INSTALLATION1. Inner sleeve flush with outer circumferenceF00J04BTYPICAL1. SpacerNOTE: Drive shaft must be removed to installspacer.Inspect PTO seal assembly. Refer to PTO HOUSING/MAGNETO SECTION.F18I0FA 1WRONG INSTALLATION1. Inner sleeve not flush with outer circumference09-03-6 LMR2004-024_09_03A.FM

Section 09 PROPULSION SYSTEMSubsection 03 (DRIVE SYSTEM)Slightly apply BOMBARDIER LUBE (P/N 293 600016) on O-rings of drive shaft.Apply a thin coat of synthetic grease (P/N 293 550010) on the O-rings of floating ring and on splinesgoing in impeller. Do not get grease on it’s sealingsurface.Slide drive shaft far enough to install floating ring.12F18I02AF18I0KA1. Synthetic grease2. No lubricationCAUTION: Note that drive shaft features a telltalegroove. If exposed after installation, the installationis wrong and PTO seal assembly willbe pressed into crankshaft splines which couldrub a hole in seal thus creating an oil leak.Continue pushing drive shaft towards engine carefullyguiding it in the PTO seal then in crankshaftsplines.Then, push drive shaft until it bottoms against theengine.While someone is pushing drive shaft, slide floatingring rearward and guide drive shaft in PTO sealassembly. It may be necessary to move PTO sealassembly up and down to position it in the sameaxis as the drive shaft.When properly aligned, maintain PTO seal assemblyin the proper position and tap shaft end until itbottoms against engine. At this time, the tell-taleMUST NOT be visible. This validates the correctposition.F18I0GA 11. Tell-tale grooveInstall PTO seal assembly.Install PTO seal support tool on PTO seal assembly.F18I0HA 1 2 31. PTO seal support2. Drive shaft end3. Insert floating ring on shaft endLMR2004-024_09_03A.FM 09-03-7

Section 09 PROPULSION SYSTEMSubsection 03 (DRIVE SYSTEM)31Install drive shaft holder tool.F18B03AF18I0IA 2GOOD INSTALLATION1. PTO seal assembly2. Shaft pushed in, hiding tell-tale groove3. Inner sleeve flush with outer circumferenceInstall Drive shaft/floating ring tool as shown. EnsurePTO seal support is still in place.Push floating ring rearwards and install C-clip.2 131F18I06AF18I0JA 2WRONG INSTALLATION1. PTO seal assembly2. Tell-tale groove visible3. Inner sleeve NOT flush with outer circumference1. Largest opening2. Install C-clipRemove drive shaft/floating ring tool, drive shaftholder then PTO seal support.NOTE: Pushing boot no. 10 rearwards will easeremoval of PTO seal support tool.09-03-8 LMR2004-024_09_03A.FM

Section 09 PROPULSION SYSTEMSubsection 03 (DRIVE SYSTEM)Now ensure everything is properly positioned: Telltale is not exposed, inner sleeve is flush with outercircumference of PTO seal assembly and C-clip isnot exposed.If tell-tale mark is exposed, push PTO seal assemblyrearwards to fully extend it.If inner sleeve is not flush, gently tap it until it isflush.Reposition splash guard.Install jet pump. Refer to JET PUMP section.Check engine oil level. Refill as necessary.Run sport boat then ensure there is no oil leak inPTO seal area.LMR2004-024_09_03A.FM 09-03-9

Section 10 STEERING SYSTEMSubsection 01 (TABLE OF CONTENTS)TABLE OF CONTENTS 0STEERING SYSTEM .............................................................................................................. 10-02-1STEERING SYSTEM INSPECTION ................................................................................... 10-02-2STEERING CABLE REPLACEMENT.................................................................................. 10-02-2STEERING HELM REPLACEMENT ................................................................................... 10-02-3ALIGNMENT .......................................................................................................................... 10-03-1VERIFICATION ................................................................................................................... 10-03-1ADJUSTMENT................................................................................................................... 10-03-1THROTTLE/SHIFTER CONTROLLER .................................................................................... 10-04-1REMOVAL........................................................................................................................... 10-04-2INSPECTION ...................................................................................................................... 10-04-2LUBRICATION .................................................................................................................... 10-04-2CABLE REMOVAL.............................................................................................................. 10-04-2CABLE INSTALLATION ..................................................................................................... 10-04-3ADJUSTMENTS ................................................................................................................ 10-04-3ASSEMBLY......................................................................................................................... 10-04-4LMR2004-030_10_01ATOC.FM 10-01-1

Section 10Subsection 02STEERING SYSTEM(STEERING SYSTEM)STEERING SYSTEM 07.5 N•m(66 lbf•in)15111614 N•m8(124 lbf•in)Woodruffkey3 N•m(26 lbf•in)1012714 20 N•m(15 lbf•ft)930 N•m(22 lbf•ft)1.7 N•m(15 lbf•in)6133 N•m(26 lbf•in)6 N•m(53 lbf•in)57.5 N•m(66 lbf•in)242.5 N•m(22 lbf•in)Silicone sealant3F13K0GS17 N•m(62 lbf•in)Loctite 243LMR2004-026-10_02A.FM 10-02-1

Section 10 STEERING SYSTEMSubsection 02 (STEERING SYSTEM)STEERING SYSTEM INSPECTIONCheck operation of steering. It must turn easilyand smoothly with a regular resistance from sideto side. Rotating resistance must be at a minimum.No friction should be felt. No frictional sound shouldbe heard. Check steering end play. If something iswrong, isolate cable from steering helm to diagnosefaulty part. Proceed as follows.Visually check cable for wear and oxidation atsteering helm and at nozzle. Check at end of cablehousing. Replace as necessary.Detach cable end from helm arm no. 11.F04K1IATYPICAL1. Remove nut and detach from arm (underneath)2. Loosen this nut to allow moving cable1F04K1JA2HELM REMOVED FOR CLARITY PURPOSE ONLY(REMOVAL IS NOT REQUIRED FOR THE VERIFICATION)1. Check for wear (particularly brass bushing wear) or oxidation inthis area1Check cable movement. Replace as necessary.Turn steering from side to side, if rotation movementis abnormal or if end play is excessive, replacesteering helm as an assembly. WARNINGDisassembly of the steering helm can lead tosteering failure. Replace complete assembly.For cable assembly, use supplied hardwareonly. Do not use substitutes.STEERING CABLE REPLACEMENTRemovalRemove nut no. 1 from bolt no. 2, then from nozzleand adjuster no. 4.Remove nut no. 3 from cable no. 5.From inside of hull, remove silicone around cable.Pull cable out of transom.Detach nut no. 10 from cable end on rotating armno. 6 to release cable.Remove nut no. 8 and no. 14 from adjuster no. 7on helm arm no. 11 to release cable no. 5.Rotate steering wheel (or shaft) to release tensionon throttle cable.Detach cable housing no. 5 from helm arm no. 11.Unscrew pivot no. 12 and adjuster no. 7 from cableto allow removal of steering cable.Remove cable from hull.InstallationReinstall removed parts and pay attention to thefollowing:– Pass cable through transom.– Screw external nut no. 3.– Position adjuster no. 4 half way on threadedlength of cable end.– Secure adjuster on nozzle.– Secure steering cable to helm.– Proceed with steering adjustment(refer to ALIGNMENT).– From inside of hull, apply Adseal 4511 (P/N 293800 033) on cable and nut area to seal hull.– Check cable/hull watertightness.10-02-2 LMR2004-026-10_02A.FM

Section 10Subsection 02STEERING SYSTEM(STEERING SYSTEM)STEERING HELM REPLACEMENTRemovalTo release steering cover, push tabs inside thenpull cover, as shown in the next photo.Once steering wheel is unlocked, remove steeringwheel puller, nut with washer and steering wheel.F09K06A 21F13K04ACAREFULLY REMOVE WITH SMALL SCREWDRIVERLoosen lock nut no. 9. Use a 19 mm (3/4 in) socket.Use of puller tool (P/N 295 000 161) is recommendedto ease steering wheel removal and to preventdamage.TYPICAL1. Loosen this nut first2. Use a 24 mm (15/16 in) socketBe careful to keep Woodruff key for reinstallation.Open driver storage cover and remove consolestorage bucket.Disconnect steering cable as described above.Remove screws no. 15 and withdraw steering helmno. 16. Pay attention, spacer(s) may be present.InstallationReinstall removed parts and pay attention to thefollowing:– Prior to installing steering helm to boat, positionrotating arm as shown.F04B0FAInstall steering wheel puller, hold steering wheelfirmly and tighten puller screw to detach wheelfrom the shaft.CAUTION: Do not hammer on the shaft to dislodgethe steering wheel.1F04K0TATYPICAL1. Correct position2. Rotating arm2LMR2004-026-10_02A.FM 10-02-3

Section 10 STEERING SYSTEMSubsection 02 (STEERING SYSTEM)– When installing steering helm to boat, reinstallspacer(s) if some were present then positionscrews no. 15 as required in slots on mountingplate to keep space between helm/cable andbody. Centering screws in slots is a good startingpoint.1F04K06A2TYPICAL1. Screw centered in slot2. Mounting plate– Torque screws as indicated in exploded view.– Ensure to install Woodruff key.– Apply anti-seize lubricant (P/N 293 800 023) onhelm shaft.– Install steering wheel.– Install lock nut and torque steering wheel nut asindicated in exploded view.– Proceed with steering alignment(refer to ALIGNMENT).10-02-4 LMR2004-026-10_02A.FM

Section 10 STEERING SYSTEMSubsection 03 (ALIGNMENT)ALIGNMENT 0VERIFICATIONPosition steering in straight ahead position.1F04K01ACheck alignment of jet pump nozzles and steeringcentering by placing a straight edge across nozzleends. Straight edge must be parallel with transomand lean on both edges of each nozzle.F13K06A 2TYPICAL1. Lock nut2. Link rodWhen finished, apply Loctite 243 (P/N 293 800 060)on lock nut threads and retighten.After adjustment, install rod ends parallel to eachother.If not enough adjustment is available, adjust cableend on steering helm arm.CAUTION: Cable end must remain protrudingthrough helm mounting block.F13K05A 1TYPICAL1. Parallel with transomADJUSTMENTLoosen lock nut of steering link rod. While holdingrod end, turn link rod to adjust.F04K1NA11. Adjust here. Cable end must remain protrudingEnsure to apply Loctite on parts as indicated onexploded view.LMR2004-026-10_03A.FM 10-03-1

Subsection 04Section 10 STEERING SYSTEM(THROTTLE/SHIFTER CONTROLLER)THROTTLE/SHIFTER CONTROLLER 01 1.3 N•m(12 lbf•in)Loctite 42534.6 N•m2(41 lbf•in)Anti-seize lubricant44.6 N•m(41 lbf•in)Install pinthen slideUP (typ.)ReverseAlternate holes may beused for variationsin cable length7.2 - 8.8 N•m(64 - 78 lbf•in)Loctite 243Reverse cableF13K0HSLMR2004-026-10_04A.FM 10-04-1

Section 10 STEERING SYSTEMSubsection 04 (THROTTLE/SHIFTER CONTROLLER)REMOVALRemove lever handles no. 3.Unscrew retaining screws no. 1 and no. 2.Pull throttle/shifter controller no. 4 out of its receptacle.CAUTION: Use a protective mat (P/N 295 000129) in shifter area when withdrawing controller.INSPECTIONCheck all moving parts for free movement and forexcessive play.Check cables for wear and oxidation.Replace parts as required.LUBRICATIONLubricate moving parts with synthetic grease(P/N 293 550 010). Where not possible, applyBOMBARDIER LUBE (P/N 293 600 016).F13K08AREMOVE LOCK PINCABLE REMOVALAt Shifter LocationF13K09AREMOVE CABLE END FROM SHIFTER1F13K07AUSE SCREWDRIVER TO SLIDE OFF LOCKING BRACKETF13K0AALOOSEN SCREW, REMOVE BRACKET AND PULL CABLE OUT1. Loosen this screw10-04-2 LMR2004-026-10_04A.FM

Subsection 04Section 10 STEERING SYSTEM(THROTTLE/SHIFTER CONTROLLER)At Jet Pump LocationDetach shifter cable from reverse gate, removeshifter cable retainer then loosen bellows. Refer toprevious pages for complete detailed procedure.12F13K0CATHROTTLE/SHIFTER CONTROLLER1. Install shifter cable in this hole2. Install throttle cables in these holesF13K0BA 121. Shifter cable2. Steering cableCABLE INSTALLATIONReverse removal procedure and pay attention tothe following:F10K0CAENSURE LOCKING BRACKET TAB IS PROPERLY LOCKED INCONNECTOR RECESSADJUSTMENTSPerform throttle and shifter cable adjustments atengine and jet pump locations.F10K0AACABLE THREADED ENDS MUST BE SCREWED AT LEAST 6TURNS INTO CONNECTORLMR2004-026-10_04A.FM 10-04-3

Section 10 STEERING SYSTEMSubsection 04 (THROTTLE/SHIFTER CONTROLLER)Shifter Cable AdjustmentShifter cable has been pre-set at the factory.Should adjustment be needed, end of cable at theshifter may be relocated as shown in the followingphoto.1Levers Friction AdjustmentFriction for shifter and throttle cables has beenpre-set at the factory.Shifter Lock AdjustmentThe locking action can be adjusted. The positionsForward/Neutral/Reverse are “notched” by meansof a steel ball no. 5 pushed by a spring no. 6against a notch on shifter plate.Turning the set screw no. 7 clockwise will increasespring pressure and therefore “hardens” shifter lockaction. Conversely turning screw counterclockwise“softens” lock action.The set screw is located on the same side asshifter lever. WARNINGEnsure to adjust shifter lock mechanism tobetween 3.9 - 4.5 kg (8 - 10 lb).F13K0DA1. Alternate cable locationsThrottle Cable AdjustmentSome throttle cable adjustment is available fromthe engine compartment. Remove rear seat storagetrays to access cables for adjustment as shownin the following photo.12F13K0FA1. Shifter lever2. Set screw (shifter lock)F13K0EA 12ASSEMBLYWhen reinstalling throttle/shifter controller no. 4,be careful not to bend cables.Ensure everything works properly.1. Starboard throttle adjuster2. Port throttle adjuster10-04-4 LMR2004-026-10_04A.FM

Section 11 HULL/DECKSubsection 01 (TABLE OF CONTENTS)TABLE OF CONTENTS 0COMPONENTS ...................................................................................................................... 11-02-1BUMPER REPLACEMENT ................................................................................................. 11-02-9DECAL REPLACEMENT..................................................................................................... 11-02-9ENGINE COVER ................................................................................................................. 11-02-10REAR LATCH ADJUSTMENT............................................................................................ 11-02-11BOW STORAGE COVER SHOCKS.................................................................................... 11-02-11BOW STORAGE COVER REMOVAL ..................................................................................... 11-02-11BILGE PUMP/DECK DRAIN AND WATER BYPASS SYSTEM OUTLETS LOCATION.... 11-02-12DRAIN TUBES REPLACEMENT ........................................................................................ 11-02-12DRAIN PLUG INSTALLATION ........................................................................................... 11-02-13SEAT AND BACKREST REMOVAL/INSTALLATION......................................................... 11-02-13ARMREST REMOVAL/INSTALLATION ............................................................................. 11-02-14SUN PAD DOORS.............................................................................................................. 11-02-15REPLACEMENT OF ENGINE COVER LATCH CABLE ...................................................... 11-02-15WINDSCREEN.................................................................................................................... 11-02-15LUBRICATION OF LOCKS ................................................................................................. 11-02-15SKI POST............................................................................................................................ 11-02-15RIDING PLATE.................................................................................................................... 11-02-16JET PUMP SUPPORT ........................................................................................................ 11-02-17FUEL PUMP MODULE REMOVAL/REPLACEMENT ........................................................ 11-02-18FUEL TANK REPLACEMENT ............................................................................................ 11-02-19ICS (INLET CLEARANCE SYSTEM) .................................................................................. 11-02-24REPAIR ................................................................................................................................... 11-03-1GENERAL ........................................................................................................................... 11-03-1TOOLS AND MATERIALS REQUIRED FOR REPAIRS...................................................... 11-03-1AIR BUBBLES .................................................................................................................... 11-03-2BLISTERS ........................................................................................................................... 11-03-3MINOR GELCOAT FRACTURES........................................................................................ 11-03-3COMPOUND FRACTURES................................................................................................ 11-03-4LMR2004-030_11_01ATOC.FM 11-01-1

Section 11 HULL/DECKSubsection 02 (COMPONENTS)COMPONENTS 0Cover13 - 16 N•m(115 - 141.6 lbf•in)5 - 6 N•m(44.2 - 53 lbf•in)Loctite243LoctiteLoctite2436 N•m(53 lbf•in)271 Silicone sealant1Loctite2434.5 N•m(40 lbf•in)32Loctite2435.5 N•m(48.6 lbf•in)13 - 16 N•m(115 - 141.6 lbf•in)Loctite 271F13L1ZSSiliconesealantLMR2004_027-11_02A.FM 11-02-1

Section 11 HULL/DECKSubsection 02 (COMPONENTS)Deck8 - 9 N•m(70.1 - 79.5 lbf•in)1.8 - 2.2 N•m(16 - 19.5 lbf•in)10Hull1.8 - 2.2 N•m(16 - 19.5 lbf•in)Hull93 - 5 N•m(26.5 - 44 lbf•in)763 - 5 N•m(26.5 - 44.2 lbf•in)118SiliconesealantSeeelectricHull1.0 - 1.5 N•m(8.8 - 13.2 lbf•in)Loctite24313Siliconesealant7.2 - 8.8 N•m(63.7 - 77.8 lbf•in)F13L20S11-02-2 LMR2004_027-11_02A.FM

Section 11 HULL/DECKSubsection 02 (COMPONENTS)Body12Body5.3 - 6.5 N•m(46.9 - 57.5 lbf•in)BodyBodyLoctite24325 N•m(18 lbf•ft)5.3 - 6.5 N•m(46.9 - 57.5 lbf•in)2122Loctite243Body2023F13L21S5.3 - 6.5 N•m(46.9 - 57.5 lbf•in)LMR2004_027-11_02A.FM 11-02-3

Section 11 HULL/DECKSubsection 02 (COMPONENTS)4Body51.1 - 1.3 N•m(9.7 - 11.5 lbf•in)5 - 6 N•m(44.2 - 53 lbf•in)Loctite2435.3 - 6.5 N•m(46.9 - 57.5 lbf•in)Loctite 243Enginecover28BodyBodyBody4BodyF13L22S11-02-4 LMR2004_027-11_02A.FM

Section 11 HULL/DECKSubsection 02 (COMPONENTS)STARBOARD VIEW2 - 3 N•m(17.7 - 26.5 lbf•in)PORT SIDE VIEWSTARBOARD VIEW1.5 - 1.9 N•m(13.2 - 16.8 lbf•in)Body2.1 - 2.3 N•m(18.5 - 20.3 lbf•in)BodyF13L23SLMR2004_027-11_02A.FM 11-02-5

Section 11 HULL/DECKSubsection 02 (COMPONENTS)45 - 55 N•m(33 - 40.5 lbf•ft)5.5 - 6.5 N•m(48.6 - 57.5 lbf•in)Loctite 2432.5 - 2.8 N•m(22.1 - 24.7 lbf•in) 5.5 - 6.5 N•m(48.6 - 57.5 lbf•in)Loctite 243F13L24S11-02-6 LMR2004_027-11_02A.FM

Section 11 HULL/DECKSubsection 02 (COMPONENTS)STARBOARD26Sundeck seatsLoctite2435 - 6 N•m(44.2 - 53.1 lbf•in)PORT SIDE26Spoiler2727SpoilerSpoilerBodyBodyBody24171516F13L25SFront seatsRear seatsLMR2004_027-11_02A.FM 11-02-7

Section 11 HULL/DECKSubsection 02 (COMPONENTS)To controlmoduleLoctite 243NOTE: Thread pivot ontocable end at least 6 threads.6 - 8 N•m(53.1 - 70.8 lbf•in)3832Loctite2432.2 - 2.8 N•m(19.4 - 24.7 lbf•in)9 - 11 N•m(79.6 - 97.3 lbf•in)Loctite2433333To powersupplyTo main harnessLoctite 2439 - 11 N•m(79.6 - 97.3 lbf•in)3131Loctite 24334F13L26S353634Loctite 243HullSeepropulsion30system HullStarboard30 2937Port side4 - 5 N•m 294 - 5 N•m(35.4 - 44.2 lbf•in) Loctite 243 (35.4 - 44.2 lbf•in)11-02-8 LMR2004_027-11_02A.FM

Section 11 HULL/DECKSubsection 02 (COMPONENTS)BUMPER REPLACEMENTBumper and TrimNOTE: Prior to beginning job, place bumper trimin a container of hot water to soften material andease installation. In cool weather, bumper rail maybe warmed too.1. Remove bumper cover no. 1 at rear of boat.2. Remove trim no. 2 from bumper rail no. 3.3. Drill pop rivets to remove bumper rail.4. Mark hole positions on body.5. Using a 4.80 mm (3/16 in) drill bit, drill a first holethrough bumper rail at any rear end. Use locatingmark as a guide and install a rivet.CAUTION: When drilling, be careful not to damagebumper rail, hull and resonators located insideengine compartment.NOTE: Check condition of silicone joint betweenhull and body. Reseal as necessary with Adseal4511 sealant (P/N 293 800 033) or equivalent withoutacetic acid vapors.6. Position bumper rail properly onto body allaround coming back to other rear end and cutexcess length if necessary.NOTE: Masking tape may be used to temporarilyretain bumper rail ahead of your work. Prior to installingtrim in bumper rail for rear corners, applyAdseal 4511 sealant (P/N 293 800 033) insidebumper rail all around boat, as shown. This is requiredso that trim properly remains attached to rail.217. Install trim using soapy water. Gently tapping trimwith a rubber hammer will help to fit trim in rail.8. Reinstall bumper cover.9. Check fit between bumper and body. Fill gapswith silicone sealant as necessary.DECAL REPLACEMENTRemovalUsing a heat gun, warm up one end of decal for afew seconds until decal can roll off when rubbingdecal edge with your finger.Pull decal slowly and when necessary apply moreheat to ease removal on the area that has to bepeeled off.If decal tears while pulling off, it has to be heatedfor a few seconds longer. If decal tends to stretchwhile pulling off, stop heating and wait a few secondsto let it cool, then peel it off.InstallationThere are 2 types of decals used on sport boats.One has a protective film on back side and theother has a protective film on both sides. They areused on 3 types of materials; plastic, gelcoat andmetal.Decals Having a Protective Film on Back SideOnlyThese decals usually contain written information(ex.: warning) and are used on gelcoat or metal.Clean surface with a good solvent such as ACRYL-ICLEAN DX 330 from PPG or equivalent (refer tomanufacturer’s instructions).Using a pencil and the new decal as a template,mark the area where decal will be located.Remove half of the decal back protective film andalign decal with marks. Start sticking it from centerand remove the other half of the film to stick itcompletely. Carefully squeegee decal beginning atcenter and working outward using, firm, short,overlapping strokes.Decals Having a Protective Film on Both SidesThese decals usually contain graphics and areused on gelcoat or plastic.F04L9OCTYPICAL1. Bumper rail2. Adseal 4511 sealant in groovesLMR2004_027-11_02A.FM 11-02-9

Section 11 HULL/DECKSubsection 02 (COMPONENTS)Installation on GelcoatClean surface with a good solvent such as ACRYLI-CLEAN DX 330 from PPG or equivalent (refer to manufacturer’sinstructions).For best result apply an activator (P/N 293 530036) to prepare the surface using a clean cloth.After a few seconds, when the activator evaporates,the surface is ready.Using a pencil and the new decal as a template,mark the area where decal will be located.For better adhesion a dry application is recommended;however, to ease decal installation a mildsolution of soapy water can be sprayed over surfacewhere decal will be installed.Remove back protective film from decal and aligndecal with marks. When well-aligned squeegeedecal beginning at center and working outward using,firm, short, overlapping strokes.Remove protective film once decal has adhered tohull.Installation on Plastic Front(front storage cover)Clean surface with isopropyl alcohol.Using a pencil and the decal as a template, markthe area where decal will be located.Apply an activator (P/N 293 530 036) to preparethe surface using a clean cloth. After a few seconds,when the activator evaporates, the surfaceis ready.CAUTION: Do not use soapy water as a cleanerto prepare the surface or to locate decal on cover.Remove back protective film from decal and carefullyalign decal with marks.Apply pressure to center of decal using a squeegeethen slide outward using a firm, short overlappingstroke. Repeat as necessary.Remove protective film from front of decal afterapplication.ENGINE COVERIf engine cover no. 4 does not lift by itself (or witha little help), when latch is released, replace gasshocks no. 5. Each shock should be checked individuallyby detaching them one at a time. At shockinstallation, position each shock so that the pistonrod is at bottom.Shocks RemovalUsing a flat screwdriver, lift tab as shown in thenext photo.F04LBHATYPICAL — LIFT TABDetach shock end.Cover RemovalNOTE: To ease working in engine compartment,it is suggested to remove engine cover no. 4 fromboat.To remove engine cover, remove both hinge pinsthen pull cover out.Another way to remove cover is to mark hinge positionwith a pencil, as shown in the next photo,then unscrew hinge from deck.F00L0KA 1TYPICAL — MARK HINGE POSITION1. Remove these three screws11-02-10 LMR2004_027-11_02A.FM

Section 11 HULL/DECKSubsection 02 (COMPONENTS) WARNINGAlways ask for help to hold engine cover whenremoving hinge pins in order to avoid personalinjuries.Cover InstallationInstallation is the reverse of removal. Ensure totorque hinge screws to 6.9 N•m (61 lbf•in).Install shocks with piston rod at bottom.REAR LATCH ADJUSTMENTEngine and Sun Pad cover latches are adjustable.If a cover is not tight enough or if it is hard to close,adjust as necessary.1. Loosen lock nut. See next illustration.2. Turn locking pin and adjustment nut as requiredand check cover fit and locking action.3. When adjustment is satisfactory, temporarilyremove lock nut and apply Loctite 243 (P/N 293800 060) on lock pin threads.4. If locking pin does not properly center in latchhole, loosen lock nut until latch may move freelysidewards.5. Close cover so that locking pin auto centers inlatch. Reopen cover and tighten locking nut inthis position.6. Torque nut to 5 N•m (44 lbf•in).1BOW STORAGE COVER SHOCKSTo remove bow storage cover shocks no. 13 proceedas follows: WARNINGMake sure to have a 2 x 4 piece of wood aroundthe work bench to support the bow storagecover while changing the cover shocks.– Open storage cover lid.– Lift locking tabs from each shock end with a flatscrewdriver and detach shock ends from mountingplates.F13L27A1. Lift each tab1Remove shock ends from fittings.Installation is the reverse of removal.At shock installation, position each shock so thatthe piston rod is at bottom.F02L25BTYPICAL — MOUNTED UPSIDE DOWN1. Locking pin2. Adjustment nut. Torque to 5 N•m (44 lbf•in)3. Lock nut32BOW STORAGE COVER REMOVALTo remove storage cover no. 12 proceed as follows:– open storage cover– Remove cover shocks WARNINGMake sure to have a 2 x 4 piece of wood aroundthe work bench to support the bow storagecover while removing the cover shocks.LMR2004_027-11_02A.FM 11-02-11

Section 11 HULL/DECKSubsection 02 (COMPONENTS)– remove 6 hinge screws.12– Disconnect drain tube from bilge pump and removetube.– Cut new tube to proper length.– Reconnect tube at each end and resecure tubewith locking ties.– Drill a 0.8 mm (1/32 in) hole where the tube isformed into a loop. This will prevent any type ofsiphoning that could occur in certain situations.– Ensure tube does not leak in bilge.1F13L27B1. Remove shocks from cover2. Remove these screwsInstallation is the reverse of removal. Pay attention totorque storage cover screws to 5.9 N•m (52 lbf•in).At shock installation, position each shock so thatthe piston rod is at bottom.BILGE PUMP/DECK DRAIN ANDWATER BYPASS SYSTEMOUTLETS LOCATIONF13L28A1. Water bypass outlet2. Deck drain outlet3. Bilge pump outletDRAIN TUBES REPLACEMENTBilge Pump Drain12 3– Disconnect drain tube no. 7 from hull fitting no. 6.Note the loop there, you will have to remake it.– Cut locking ties all along drain tube from transomtoward bilge pump.F10L2IATYPICAL — PROPER TUBE INSTALLATION1. Drill hereDeck Drain– Disconnect drain tube no. 9 from transom fittingno. 8.– Cut locking ties all along drain tube from transomtoward deck storage compartment.– From engine compartment, disconnect drain tubefrom deck fitting no. 10.– Cut new tube to proper length.– Reconnect tube at each end and resecure withlocking ties.– Ensure tube does not leak in bilge.Scupper ValveCheck that ball is clean and moves freely.RemovalRemove all 4 screws retaining existing scupper valveno. 11.11-02-12 LMR2004_027-11_02A.FM

Section 11 HULL/DECKSubsection 02 (COMPONENTS)1DRAIN PLUG INSTALLATIONRefer to the following illustration to install drainplug no. 14.21F04LBKATYPICAL1. Remove all 4 screwsInstallationInstall valve membrane taking care to properly positionmembrane lip facing ball. Ensure membranepositioning holes are properly aligned with valveknob. See next photo.CAUTION: Make sure to assemble all the partsexactly in the same position as illustrated. Ifscupper valve is assembled wrong, water willseep through.23F04LC1A1. Drain plug2. Torque screws to 1.0 - 1.5 N•m (8.9 - 13 lbf•in)3. HullSEAT AND BACKRESTREMOVAL/INSTALLATIONDriver Seats3Both driver seat cushions no. 18 are secured withpop rivets. To detach backrest cushion, drill outpop rivets as shown in the next photo.21F04L9VB11. Ball2. Membrane lip3. Membrane positioning hole aligned with valve knobCarefully clean the inside of the plastic bushing.Install scupper valve assembly onto plastic fitting.Secure using screws.Tighten screws as specified in exploded view.F13L29ATYPICAL1. Remove these rivetsLMR2004_027-11_02A.FM 11-02-13

Section 11 HULL/DECKSubsection 02 (COMPONENTS)Use a 4.75 mm (3/16 in) drill bit.To remove seat cushion no. 19, drill out rivets onboth sides of seat bucket and lift cushion out.Front Backrest CushionsPort front backrest cushion no. 24 is removed byfirst removing the front port cup holder.Using an 11 mm wrench, loosen and remove nutand washer from center of backrest cushion.Lift cushion at each end up and away from gunwale.Starboard front backrest no. 24 is removed by firstopening the starboard console cover (windscreen).Remove storage bucket.Loosen and remove nut and washer as above.Lift cushion at each end up and away from gunwale.Darts may need to be replaced. Use P/N 293 730021.ARMREST REMOVAL/INSTALLATIONArmrestsArmrests no. 17 are secured to deck with dartsand S-clip. Carefully pry darts from deck as shownin the next photo.1Front Seat CushionsTo remove front seat cushions no. 25, unsnap fasteners,lift cushion and pull away from retainingblocks.To install front seat cushions, place cushion intoposition with retaining blocks and snap fasteners.Rear Backrest CushionsRear backrests no. 15 are secured with darts andS-clips.To remove, pull backrest from bottom to releasedarts and lift upwards to release from S-clip.To install, position cushion onto S-clip and pushdown. Align darts with mounting holes and tapinto position with a rubber mallet.F13L2BATYPICAL1. Lift pad along edgePull inner side of armrest towards self and lift upand away from S-clip.To install, position darts 1/2 way into holes. Positionside of armrest over S-clip and push downwards.Tap darts into place with a rubber mallet.F13L2AATYPICAL11-02-14 LMR2004_027-11_02A.FM

Section 11 HULL/DECKSubsection 02 (COMPONENTS)SUN PAD DOORSOpen sun pad doors no. 26.Lift tabs from each shock no. 27 and detach frommounting bracket.Remove bolts from door cover hinges.1F13L2CA22 21. Lift tabs and remove shocks2. Remove these screwsREPLACEMENT OF ENGINECOVER LATCH CABLERemove latch mechanism no. 28 from body andopen it by removing the plate underneath.Detach cable end from the rod.21Tape the end of the new cable to the end of the oldcable. Detach front portion of cable in front portstorage compartment and pull cable toward frontthus pulling the new cable at the same time.CAUTION: Existing cable is attached with lockingties, use extreme caution when pulling toinsert new cable.Complete parts assembling in the reverse order ofdisassembly.WINDSCREENCleaningFirst rinse with fresh water to remove dried saltwater.Wash with Bombardier cleaner (P/N 293 110 001).Clean only with flannel clothes or Kimtowels ®wipes no. 58-380 from Kimberly-Clark.CAUTION: It is necessary to use flannel clothsor “Kimtowels” wipes on windscreen to avoiddamaging surface.To remove scratches on windscreen: Start with“Slip Streamer Motorcycle Windshield Heavy DutyScratch, Remover”. Finish with “Slip Streamer MotorcycleCleaner and Polish”.NOTE: The later product may be used alone if onlylight scratches are noticeable.CAUTION: Never clean windscreen with strongdetergent, degreasing agent, paint thinner, acetone,products containing chlorine, etc.LUBRICATION OF LOCKSLocks should be lubricated with BOMBARDIERLUBE lubricant (P/N 293 600 016) to keep themworking properly. This will help dissolving dried saltwater.F04L7HA 11. Detach cable end from rodSKI POSTRemovalFrom inside engine compartment, remove ski postlock no. 20 and loosen collar stop screws no. 21,lift and pull out ski post assembly.LMR2004_027-11_02A.FM 11-02-15

Section 11 HULL/DECKSubsection 02 (COMPONENTS)Refer to the following photo sequence for detailedprocedure.Check post operation.Secure ski post lock using latch.F13L2MATYPICAL1. Ski post lock2. Pull latch to remove ski post lock21OperationInner post must move up and down and stop whenreaching ski post lock.RIDING PLATERemovalRemove jet pump. Refer to JET PUMP.NOTE: When drive shaft is removed, some oil willflow out. To prevent this, start engine, run at 4000RPM for 10 seconds and stop engine at this RPM.This will move oil out of PTO housing into oil tank.Remove the speed sensor from the riding plate (ifapplicable).Loosen and remove riding plate screws.NOTE: An impact screwdriver should be used toloosen tight screws.Using a low height hydraulic bottle jack and 2 steelplates, pry out riding plate.F04LBSA1LOOSEN BOLTS THEN REMOVE POST ASSEMBLY1. Ski post deck boltsDisassemblyPull inner post no. 22 out of outer post no. 23.InstallationInstallation is essentially the reverse of removalprocedure. However pay attention to the following.Torque collar stop screws to 5.9 N•m (52 lbf•in).Apply BOMBARDIER LUBE lubricant (P/N 293 600016) to inner ski post before returning if to outerpost.F13L2NATYPICAL1. Hydraulic bottle jack2. Riding plateCleaning1– Scrape off all excess of sealant from riding plateand hull.– Clean hull surface with an acetone based solventto eliminate grease, dust and any residueof sealant.211-02-16 LMR2004_027-11_02A.FM

Section 11 HULL/DECKSubsection 02 (COMPONENTS)InstallationApply Loctite RTV silicone sealant (P/N 293 800066) as indicated by the shaded areas in the nextillustration.513– Remove boot, pivot, nut and washer from reversecable. Remove from transom.– Disconnect water supply hose, water return hoseand bailer hoses.144422355662F13L2DA3TYPICAL1Follow the torque sequence shown.Torque screws to 9 - 11 N•m (79.6 - 97.3 lbf•in).JET PUMP SUPPORTRemoval– Remove jet pump. Refer to JET PUMP.– Remove inlet grate and riding plate.– Remove ball joint, nuts, and washer from steeringcable. Remove from transom.F13L2OATYPICAL1. Bailer plug2. Coolant inlet3. Coolant return4. Water inlet5. Water outlet– Remove nuts, lock washers and flat washersretaining jet pump support from inside hull.11F04LCNATYPICAL1. Remove from support and transom2. Remove from support and transom2F04LBVATYPICAL1. Remove nuts– Using a heat gun, heat jet pump support until itis possible to pull it.NOTE: Shims may have been installed betweensupport and body. Do not remove these shims,otherwise jet pump alignment will be altered.LMR2004_027-11_02A.FM 11-02-17

Section 11 HULL/DECKSubsection 02 (COMPONENTS)InstallationApply Loctite RTV silicone sealant (P/N 293 800066) as indicated by the shaded areas in the nextillustration. Follow the torque sequence shown.1 2To remove front fuel pump module it will be necessaryto install scissors jack on starboard side offront module between fuel tank and deck.13F18L28A 4FUEL PUMP MODULEREMOVAL/REPLACEMENTRemovalRemove rear seat cushions no. 16 and storage tubs.With engines in place, remove rear fuel pumpmodule.Rear fuel pump module is removed to insure frontstud ring is reinserted properly.Remove nuts, washers and gasket from stud ringand carefully lift fuel pump module from tank whilerotating module 180° in order to allow fuel floatclearance out of tank.1F13L2EA1. Scissors jack installedOpen jack to increase clearance for module removalpast and over starboard side of tank nearjack.Open jack carefully and with minimum expansionnecessary for fuel pump module removal.Damage to the fuel pump module can occur if toomuch pressure is applied from the jack.Remove nuts, washers and gasket from stud ringand carefully lift fuel pump module from tank whilerotating module 180° in order to allow fuel floatclearance out of tank.ReplacementNOTE: Front fuel pump module float points toPORT.NOTE: Rear fuel pump module float points toSTARBOARD.NOTE: Gasket fits on stud ring only one way withgasket tab tell-tale in the up position. Align arrowof each fuel pump module with gasket tab.Insert front module from starboard side with scissorsjack installed. Align with studs. Reachthrough rear module hole and ensure that frontmodule studs are properly seated.F13L2FA1. Fuel float11-02-18 LMR2004_027-11_02A.FM

Section 11 HULL/DECKSubsection 02 (COMPONENTS)Lube studs thoroughly with Loctite 518.1F13L2PALOCTITE 518 ON RING STUD THREADSInstall fuel pump module gasket over ring studs,with tab tell-tale pointing upwards.Install washers and nuts and cross-tighten tospecified torques and sequence.Remove scissors jack.Install rear module from starboard side at an anglefor clearance purposes.Carefully push pump down over stud ring withoutdislodging studs.Lube studs thoroughly with Loctite 518 as shownabove.Install fuel pump module gasket over ring studs,with tab tell-tale pointing upwards.Install washers and nuts and cross-tighten to specifiedtorques and sequence.Reinstall any fittings loosened during procedure.Pressurize fuel system and inspect for leaks as perprocedure in FUEL CIRCUIT SECTION.NOTE: It will be necessary to install the Fuel systempressurization retainer (P/N 529 035 978) asshown in the photo below before performing thefuel system pressurization test.F13L2QA1. Fuel system pressurization retaining bracket in positionThis retaining bracket prevents the fuel pumpmodules from being dislodged from their respectivetank detents during the pressure test.FUEL TANK REPLACEMENTEngine Cover RemovalNOTE: To ease working in engine compartment,it is suggested to remove engine cover no. 4 fromboat.Using a flat screwdriver, lift tab as shown in thenext photo.F04LBHATYPICAL — LIFT TABLMR2004_027-11_02A.FM 11-02-19

Section 11 HULL/DECKSubsection 02 (COMPONENTS)Detach each shock end from engine cover.To remove engine cover, remove both hinge pinsthen pull cover off.NOTE: Always ask for help to hold engine coverwhen removing hinge pins in order to avoid personalinjuries.Another way to remove cover is to mark hinge positionwith a pencil, as shown in the next photo,then loosen screws and remove hinge from deck.NOTE: Following procedures to be performed oneach engine.Remove venturi and reverse gate supports fromeach engine. Both units remain connected.F13L2GATYPICALRemove the 4 retaining nuts from each pump.F00L0KA 1TYPICAL — MARK HINGE POSITION1. Remove these three screws from each hingePump RemovalRemove shifter and steering cables from starboardreverse gate and nozzle.F13L2HATYPICALPull out pumps.F04J4BA 12TYPICAL — DISCONNECT STEERING AND REVERSE CABLES1. Shifter cable2. Steering cable11-02-20 LMR2004_027-11_02A.FM

Section 11 HULL/DECKSubsection 02 (COMPONENTS)Floating Ring and PTO SealCAUTION: Strictly follow this procedure otherwisedamage to component(s) might occur.Lift splash guard to expose PTO seal assembly.Install PTO seal support tool (P/N 529 035 842) onbottom of PTO seal assembly as shown.11F18B02A1. Drive shaft holderNOTE: This is necessary so the drive shaft cannotmove rearwards when using the drive shaft/floating ring tool.F18B01A1. PTO seal support toolF18B03ATYPICAL1F18I04A1. Insert in groove of PTO seal assemblyInsert drive shaft holder (P/N 529 035 871) onpump support as shown.F18B04ADRIVE SHAFT/FLOATING RING TOOLLMR2004_027-11_02A.FM 11-02-21

Section 11 HULL/DECKSubsection 02 (COMPONENTS)Install drive shaft/floating ring tool (P/N 529 035 841)as shown.1212F18I05A1. Largest opening here2. Floating ringTurn screw clockwise so that the tool pushes thefloating ring rearwards to expose the C-clip. DoNOT remove clip at this time.NOTE: This step is done to ensure floating ring isfree and not stuck on the drive shaft.Remove drive shaft/floating ring tool and driveshaft holder.Reinstall drive shaft/floating ring tool as shown.F18I08A1. Largest opening here2. Lubricate both O-ringsTurn screw clockwise so that the tool pushes thePTO seal forward and the drive shaft to the rear toexpose both O-rings. Lubricate O-rings withBombardier Lube (P/N 293 600 016).NOTE: This is necessary to ease drive shaft removallater.11-02-22 LMR2004_027-11_02A.FM

Section 11 HULL/DECKSubsection 02 (COMPONENTS)Remove drive shaft/floating ring tool and PTO sealsupport.Drive ShaftSimply pull out drive shaft.Place rags under PTO housing to prevent spillage.If spillage occurs, clean immediately with the pulleyflange cleaner (P/N 413 711 809) to prevent oilstains.NOTE: It may require a slight jerk rearwards to removethe O-rings from the PTO seal assembly.EnginesClamp off port and starboard heat exchanger coolanthoses using four hose clamps (P/N 529 032500).F18B03ATYPICALReinstall drive shaft/floating ring tool as shown.Push floating ring rearwards to expose C-clip andremove it.1 221F13L2IAF18I0BA1. Largest opening here2. Remove C-clipRemove drive shaft holder tool then drive shaft/floating ring tool.NOTE: Use this sequence to minimize the amountof movement the drive will slide back into PTOseal assembly.1. Clamp off Port hoses2. Clamp off Starboard hosesRemove exhaust hoses from the tuned pipes andthe center mufflers. Remove two center mufflersfrom engine compartment.At this point, loosen and remove hoses previouslyclamped off from heat exchanger fittings.Pull coolant expansion tanks from wall bracketsand lay atop engines.Remove starter cables, all electrical connectionsand both harnesses.Cut all necessary locking ties.Remove throttle cables.Remove engine-to-engine grounding strap.Loosen and remove TOP motor mount bolts. Donot remove motor mounts from hull. This allowsremoval of engines while allowing any alignmentshims installed beneath the mounts to remain inplace.Remove engines, marking Port and Starboard enginesfor alignment purposes.LMR2004_027-11_02A.FM 11-02-23

Section 11 HULL/DECKSubsection 02 (COMPONENTS)For further information regarding reinstallation andalignment, refer to REMOVAL AND INSTALLATIONsection.Fuel TankSiphon fuel tank.Remove all hoses and wiring harness connectorsfrom fuel tank and fuel pump modules.Loosen fuel tank strap bolts from hull at rear of fueltank.F13L2LAF13L2JA1. Loosen and remove bolts1Mark or scribe locations of front motor mounts.Identify Port and Starboard mounts and any shimsfor reinstallation.Remove front motor mounts, port and starboard.TYPICALInstallation is reverse of this removal procedure.Reinstall all fittings to their proper torques.Apply Loctite 271 to fuel tank strap mounting bolts.Apply Loctite 243 to motor mount bolts.Apply Loctite 243 on reverse gate Allen bolts.Apply Loctite anti-seize on 4 pump mounting studs.ICS (Inlet Clearance System)OperationThe ICS (Inlet Clearance System) is an electricallycontrolleddevice for removal of weeds and otherdebris picked up by the action of the jet pump.The actuator switch is located next to the driverseat below the throttle/shifter as shown below.121F13L2KA1. Port front motor mount2. Starboard front motor mountPull tank from hull.F13L2RATYPICAL1. ICS switch11-02-24 LMR2004_027-11_02A.FM

Section 11 HULL/DECKSubsection 02 (COMPONENTS)Shifter must be in NEUTRAL position in order tooperate ICS.NOTE: With shifter in NEUTRAL position, pressand hold ICS button for 10 seconds. This allowsgrates to fully extend. Release ICS button and wait10 seconds BEFORE shifting from NEUTRAL toallow grates to fully close. Repeat as needed toclear system. Never shift into Forward or Reversewhile activating the ICS. This can leave the gratesin the down position and create a hazardous operatingcondition. The ICS must be fully retractedbefore operating the vehicle.Cable ReplacementNOTE: Following procedure to be performed foreach cable.Remove bolt and nylon washer no. 29 from ICSgrate and joint fitting no. 30.Remove joint fitting no. 30 from end of cable.F13L2TA1TYPICAL1. Loosen cable lock2. Pull cable up through hullTie a line to end of cable for later retrieval if replacementis necessary.From front starboard console access, remove pivotarm bolt no. 32 from pivot arm no. 38.Loosen locking nuts no. 33 from ICS mounting platform.22211F13L2SA1. Remove this bolt and washer2. Remove this fittingLoosen cable lock no. 31 from hull inside enginecompartment near drive shaft.Pull cable up through hull into engine compartment.F13L2UA1. Remove this bolt2. Loosen these nutsPull cable out from starboard console access compartment.LMR2004_027-11_02A.FM 11-02-25

Section 11 HULL/DECKSubsection 02 (COMPONENTS)Using line previously tied to cable end, attach tonew cable and pull new cable through to enginecompartment.Insert cable through cable lock no. 31, and installhalf-rings no. 34.Insert cable through rubber washer and throughhull.Apply Loctite 243 to cable threads and screw ontojoint fitting no. 30 as far as possible.Insert screw through nylon washer and into tineslot shown below.Tighten screw to 4 - 5 N•m (35.4 - 44.2 lbf•in).From inside starboard console access, insert cableinto appropriate slot on ICS support bracket no. 35.The Port cable is placed in the Port slot no. 36.The Starboard cable is placed in the Starboard slotno. 37.121F13L2UBF13L2SBTYPICAL1. Tine slot with cable end installed1. Port slot2. Starboard slotPlace the cable end(s) in the pivot arm and installthe pivot arm bolt no. 32 through the cable end(s).Tighten to 6 - 8 N•m (53.1 - 70.8 lbf•in).Adjust cable(s) to pull the ICS grate(s) level withthe ride plate.Tighten cable lock nut(s) in this position to 9 - 11 N•m(79.6 - 97.3 lbf•in).11-02-26 LMR2004_027-11_02A.FM

Section 11 HULL/DECKSubsection 03 (REPAIR)REPAIR 0GENERALGelcoat is the smooth and durable cosmetic finishwhich coats the fiberglass hull and body of a Sea-Doo sport boat. It also provides a protective barrieragainst water and sun. It consists of a mixture ofresin, pigment (coloring), fillers, monomers andcatalyst which is sprayed into the mold.The body and hull of the Sea-Doo sport boat areconstructed of chopped fiberglass, saturated withresin. It is sprayed on the layer of gelcoat alongwith pieces of fiberglass mat, cloth and wovenroving which are added at required areas. Thistype of construction is very accommodating forhigh quality repairs. With patience, the propertechniques and materials, a damaged area can berestored to an original finish.The content presented here is not intended to replacethe use of a complete fiberglass and gelcoatrepair manual. Its main purpose is to help you understandwhat factors are involved when makinga damage assessment or estimate.All requests for Gelcoat repair or factory colormatch should be made directly to Gelcote InternationalLTD. They are set up to handle all requestsand as a Gelcoat supplier, they can respond to allneeds and questions with greater product knowledge.NOTE: Fiberglass repair kit is available through automotiveor marine suppliers. Gelcote ® repair kitsare available through the regular channels. WARNINGProtect skin. Wear gloves when in contactwith resin, hardeners and gelcoat. A barrierskin cream may also be used. Do not exposework area to open flame or a lit cigarette.Some of the materials are flammable. Protecteyes. Wear safety glasses when grinding,sanding or spraying. Use a dust mask whensanding or grinding. When spraying wear arespirator or paint mask. Always read warninglabels on products.For all Gelcoat requests, please contact the following:Gelcote International LTD29-174 Colonnade RD SouthNepean, Ontario, K2E 7J5CanadaPhone: (613) 225-2177Fax: (613) 225-5297Canadian and North American toll free:1 877 435-2683E-Mail: Gelcote@comnet.caWeb site address: www.comnet.ca\~gelcote\TOOLS AND MATERIALSREQUIRED FOR REPAIRSTools– safety glasses– air mask– white cloths– sanding block– putty knife– plastic film– stirring stick– scissors– buffing pad– heavy-duty polisher– power sander– paint brush– plastic container (mixing)– spray gun– plastic squeegee.LMR2004_027-11_03A.FM 11-03-1

Section 11 HULL/DECKSubsection 03 (REPAIR)Materials– fiberglass mat– fiberglass cloth– polyester resin– cardboard– masking tape– sandpaper (100-grit, 220-grit, 320-grit, 400-grit,600-grit, 1000-grit)– 24-grit sanding disks– gelcoat putty– liquid gelcoat– acetone– cabosil– epoxy filler– medium compound (white)– fine compound (white)– wax.2. Filling the CavityThe prepared surface must be cleaned with acetoneon a cloth. Use the Gelcote ® repair kit. Followthe mixing instructions in the kit when preparingthe gelcoat putty.Carefully mix the required amount while makingsure there are no air bubbles in the mixture. Witha putty knife fill the repair area, as shown in thenext photo, and cover with a plastic film to smoothsurface. Curing time may depend on temperature,amount of putty and percentage of catalyst.After 2 hours, press lightly on the surface with fingersto test the hardness. When the area becomeshard, remove the plastic film.AIR BUBBLESPossible Cause– Air pocket trapped between layers of laminateand gelcoat.1. Preparation of SurfaceRemove all of the damaged gelcoat surroundingthe air bubble with a putty knife or preferably acarbide grinding tip. Make sure all loose and weakareas are completely removed. Sand a small areaof the gelcoat surface with 220-grit sandpaper. Ifneeded, sand the cavity itself. These areas musthave a rough surface to allow the gelcoat putty tobond properly.F09L30ADAMAGED AREA FILLED3. SandingBegin block sanding the patch with 320-grit sandpaperuntil you come close to the original surface.Remove dust with a water soaked cloth and continuesanding with a 400-grit wet paper. Finish wetsanding with a 600-grit to remove deeper scratches.If needed you can wet sand with finer grit papersuch as 1000-grit.4. Buffing and WaxingBuff the surface using a heavy duty polisher witha buffing pad. Make sure the pad is free of dirt oryou may damage the gelcoat. Carefully begin buffingwith a white medium compound RM 856. Finishoff using a fine RM 852 compound. While buffing,pay close attention to avoid overheating thesurface.F09L2ZAREMOVE DAMAGED GELCOAT11-03-2 LMR2004_027-11_03A.FM

Section 11 HULL/DECKSubsection 03 (REPAIR)BLISTERSPossible Causes– Inert catalyst.– Improper catalyst/gelcoat ratio.A blister is a visible bump on the Sea-Doo sportboat surface that may not necessarily come rightthrough the gelcoat layer. If there are only a fewblisters, you may follow the same repair procedureas for air bubbles. If they are numerous andin close concentration, you may have to spray liquidgelcoat to achieve proper repair. This procedureis covered in the next problem.CAUTION: Ensure blistered area is completelydry before attempting repairs.MINOR GELCOAT FRACTURESPossible Causes– Flexing of fiberglass laminate.– Gelcoat thickness.– Direct result of impact.In case of fractures which have not penetratedpast the gelcoat layer, the repair concerns thegelcoat only. If flex cracking or impact are evident,then additional reinforcement may be necessary.This subject will be covered in the next problem.1. Preparing the SurfacesSmall FracturesOpen the cracks up with a sharp triangular canopener or preferably a carbide tipped die grinder.The V groove will provide a good bonding area forthe gelcoat. With 220-grit sandpaper, sand thesides of the notched-out areas.Numerous FracturesUsing a grinder with a 24-grit disk, remove thegelcoat. Sand the edge area with 220-grit sandpaper.2. Filling the Repair AreaSmall FracturesRefer to the same procedure as in the air bubbles.Numerous Fractures Over Large SurfacePrepare the area for spray application of liquidgelcoat. Wipe down the surface with acetone.Mask the surrounding area to protect the boat fromoverspray.Mix the needed quantity of gelcoat and catalystaccording to supplier’s recommendations. Thegelcoat can be thinned with acetone up to 10%. Ifit needs more consistency you can add cabosil.Make sure that the air supply is free of oil, dirt andwater.Test spray the gelcoat mixture on paper to verifyits consistency and pattern. You may have to apply5 or 6 coats to cover the area properly. Overlapeach coat further than the last, leaving at least 30seconds between passes. Avoid trying to coat thesurface with only a few heavy coats, as this willnot allow the gelcoat to dry properly.Apply a coat of polyvinyl alcohol to seal off the airand protect the gelcoat surface from dust. PVAspeeds up the curing process because gelcoat willnot cure properly when exposed to air.3. SandingWash the polyvinyl alcohol off with water. Dependingon the size of the area repaired, you can eitherblock sand as per previous procedure or you mayuse an air sander. Sand the surface down with progressivelyfiner grits of sandpaper until the desiredfinish is achieved.4. Buffing and WaxingBuff the surface using a heavy duty polisher witha buffing pad. Make sure the pad is free of dirt oryou may damage the gelcoat. Carefully begin buffingwith a white medium compound RM 856. Finishoff using a fine RM 852 compound. While buffing,be careful not to overheat the surface.LMR2004_027-11_03A.FM 11-03-3

Section 11 HULL/DECKSubsection 03 (REPAIR)COMPOUND FRACTURESPossible Causes– Thickness of fiberglass laminate.– Direct result of impact.Compound fractures are those that have gone pastthe gelcoated surface and in through the layers offiberglass laminate. Two types of repairs have tobe performed. The first is to restore the structuralintegrity of the damaged area. Fracture types canvary from a simple crack to a large hole. Usually,fiberglass reinforcement becomes necessary, especiallyif the fracture can be attributed to weakness.The final part of the repair is the gelcoating,which cannot be applied until the interior and exteriorlaminate surfaces have been repaired.OutsideRemove the damaged gelcoat and fiberglass witha 24-grit disk using a power sander. Grind outwardat least 2 inches from the fracture to allow thepatch to bond to strong material. Cut enough piecesof fiberglass mat necessary to build up the area.The pieces should be cut so they overlap each otherby at least half an inch. For a smoother finish,the last layer should be fiberglass cloth. If the fractureis small enough all you may have to do is fillthe area with an epoxy filler.InsideFor the interior repair, you can grind more. This willallow for more fiberglass material which willstrengthen the area. If the fracture opening is toolarge after surface preparation, you may need abacking support to cover the opening. Cut alternatingpieces of fiberglass mat and cloth in overlappingsizes.Using a clean paintbrush, brush the mixed resin onthe surface. Place the smallest piece of mat overthe fracture and then wet out the mat. Follow withthe remaining pieces of mat and final layer of cloth.While wetting the pieces make sure you work theair bubbles out and saturate all the pieces evenly.Try to work quickly, you may only have 15 or 20minutes. You may clean the brush with acetone.Wait until the repair has hardened before movingon to the interior repair. If the size of the openingis too large for the pieces to maintain the propershape, you will have to use a backing support. It isa shaped piece of cardboard that fits flush to theinterior surface and has a plastic layer on the repairside. It is held in place by tape or a support.InsideWipe down the area with acetone on a cloth. Applythe same procedure as for outside repair whenlaminating the alternating pieces of fiberglass material.If a backing support was used, remove itbefore starting the repair. After the area has hardened,remove sharp edges of material from surface.If required paint the surface.SandingOutsideThis surface will have to be prepared for applicationof gelcoat. The size of the area will determinethe gelcoating procedure to be used. Refer to therepair procedure for minor gelcoat fractures.Buffing and WaxingRefer to the buffing and waxing for minor gelcoatfractures. If painting the exterior is preferred, referto PAINTING subsection.Patching the Repair AreaOutsideThe outside should be done first. Wipe clean thearea with acetone on a cloth, then mask off area.For a small crack use an epoxy filler in the sameway you would use Bombardier gelcoat repair putty.When laying up a larger area you will use mat,cloth and fiberglass resin and hardener. Use aclean container to mix the resin, mix only what youwill need. Follow the recommended catalyst ratio.11-03-4 LMR2004_027-11_03A.FM

Section 12 TECHNICAL DATASubsection 01 (SPEEDSTER 200)SPEEDSTER 200 0ENGINE SPEEDSTER 200Number of engines 2Engine typeBOMBARDIER-ROTAX 1503 4-TEC, 4-stroke,Over Head Camshaft (OHC), liquid cooled (x 2)Number of cylinders 3 (x 2)Number of valves12 valves with hydraulic lifters (no adjustment)Bore Standard 100 mm (3.9 in)Stroke63.4 mm (2.49 in)Displacement1498 cm³ (91.41 in³)Compression ratio 10.6 ± 0.4:1Rev limiter setting7650 ± 50 RPMLubricationDry sump with replaceable oil filter4-stroke engine oil SAE 10W40(API Service classification SG, SH or SJ)Oil filterCHAMPIONExhaust system Type Water cooled, water injected with regulatorIntake valve opening10° BTDCIntake valve closing45° ABDCExhaust valve opening50° BBDCExhaust valve closing5° ATDCStarting systemElectric startNew minimum5.961 mm (.2347 in)IntakeNew maximum5.975 mm (.2352 in)Valve stem diameterWear limit5.930 mm (.2330 in)New minimum5.946 mm (.2341 in)Exhaust New maximum5.960 mm (.2346 in)Wear limit5.930 mm (.2330 in)New minimum5.994 mm (.2360 in)Valve guide diameterNew maximum6.018 mm (.2369 in)Wear limit6.060 mm (.2386 in)Valve spring free lengthInnerNew nominal41.02 mm (1.615 in)Wear limit38.8 mm (1.499 in)OuterNew nominal45.45 mm (1.789 in)Wear limit43 mm (1.693 in)Valve seat contact widthIntakeNew nominal1.1 to 1.3 mm (.043 to .051 in)Wear limit1.6 mm (.063 in)ExhaustNew nominal1.25 to 1.55 mm (.049 to .061 in)Wear limit1.8 mm (.071 in)New minimum20.007 mm (.7876 in)Rocker arm bore diameterNew maximum20.020 mm (.7881 in)Wear limit20.035 mm (.7887 in)New minimum19.980 mm (.7866 in)Rocker arm shaft diameterNew maximum19.993 mm (.7871 in)Wear limit19.965 mm (.7860 in)LMR2004-028_12_01A.FM 12-01-1

Section 12 TECHNICAL DATASubsection 01 (SPEEDSTER 200)ENGINE SPEEDSTER 200Cylinder head screw Service limit 148.5 mm (5.846 in)1 st RectangularPiston ring type and quantity2 nd Taper-face3 rd Oil scraper ringRectangular0.15 mm (.006 in)Taper-face New minimum0.15 mm (.006 in)Oil scraper ring0.15 mm (.006 in)Ring end gapRectangular0.3 mm (.012 in)Taper-face New maximum0.3 mm (.012 in)Oil scraper ring0.4 mm (.016 in)All Wear limit 1.5 mm (.06 in)Rectangular0.025 mm (.001 in)Taper-face New minimum0.015 mm (.0006 in)Oil scraper ring0.02 mm (.0008 in)Ring/Rectangular0.07 mm (.0028 in)piston groove clearanceTaper-face New maximum0.06 mm (.0024 in)Oil scraper ring0.055 mm (.0021 in)All Wear limit 0.15 mm (.006 in)Piston/cylinder wall clearanceNew minimum 0.024 - 0.056 mm (.001 - .0022 in)Wear limit0.1 mm (.0039 in)Cylinder taper (maximum)0.03 mm (.0011 in)Cylinder out of round (maximum)0.008 mm (.0003 in)New minimum24.939 mm (.9818 in)FrontNew maximum24.960 mm (.9827 in)Wear limit24.930 mm (.9815 in)Camshaft bearing journalNew minimum39.892 mm (1.5705 in)PTO andNew maximum39.905 mm (1.5711 in)centerWear limit39.885 mm (1.5703 in)New minimum25.000 mm (.9842 in)FrontNew maximum25.013 mm (.9848 in)Wear limit25.025 mm (.9852 in)Camshaft boreNew minimum40.000 mm (1.5748 in)PTO andNew maximum40.016 mm (1.5754 in)centerWear limit25.025 mm (1.5758 in)New minimum31.480 mm (1.2394 in)IntakeNew maximum31.590 mm (1.2437 in)Cam lobeWear limit31.430 mm (1.2374 in)New minimum31.699 mm (1.2480 in)Exhaust New maximum31.809 mm (1.2523 in)Wear limit31.650 mm (1.2461 in)Crankshaft axial clearanceNew minimum0.08 mm (.0031 in)New maximum0.22 mm (.0087 in)Connecting rod big end clearance Wear limit 0.09 mm (.0035 in)12-01-2 LMR2004-028_12_01A.FM

Section 12 TECHNICAL DATASubsection 01 (SPEEDSTER 200)ENGINE SPEEDSTER 200New minimum49.984 mm (1.9679 in)Crankshaft journal diameterNew maximum50.000 mm (1.9685 in)Wear limit49.950 mm (1.9665 in)Crankshaft radial clearance Wear limit 0.007 mm (.0028 in)Connecting rod big end diameter Service limit 45.080 mm (1.7740 in)Connecting rod big end clearance Service limit 0.09 mm (.0035 in)New minimum0.135 mm (.0053 in)Connecting rod big end axial playNew maximum0.287 mm (.0113 in)Wear limit0.500 mm (.0197 in)Crankshaft deflection0.050 mm (.002 in)New minimum23.010 mm (.9059 in)Connecting rod small end diameterNew maximum23.020 mm (.9063 in)Wear limit23.070 mm (.9080 in)New minimum22.996 mm (.9053 in)Piston pin diameterNew maximum23.000 mm (.9055 in)Wear limit22.990 mm (.9051 in)Piston pin bore clearance Wear limit 0.080 mm (.0035 in)New minimum31.984 mm (1.2592 in)Balance shaft journal diameterNew maximum32.000 mm (1.2598 in)Wear limit31.950 mm (1.2579 in)Balance shaft radial clearance Wear limit 0.07 mm (.0028 in)Balance shaft axial clearanceNew minimum0.02 mm (.0008 in)New maximum0.25 mm (.0098 in)ADDITIONAL INFORMATION:LMR2004-028_12_01A.FM 12-01-3

Section 12 TECHNICAL DATASubsection 01 (SPEEDSTER 200)ELECTRICAL SPEEDSTER 200Magneto generator output380 W @ 6000 RPMIgnition system typeDI (Digital Induction)Ignition timingNot adjustableSpark plugMake and typeNGK DCPR8EGap0.75 mm (.030 in)Generating coilN.A.Battery charging coil0.1 - 1.0 ΩIgnition coilPrimary0.45 - 0.55 ΩSecondary6.8 - 10.2 kΩEngine RPM limiter setting7650 RPMBattery12 V, 30 A•h (not supplied)TOPS10 ABattery fuse (rectifier)30 ACylinder 1, ignition coil and injection10 ACylinder 2, ignition coil and injection10 ACylinder 3, ignition coil and injection10 AElectric bilge pump (2)7.5 AStarting system, electric fuel pump10 AECM, start/stop circuit5 AMain (engine fuse block) 15 AFusesCharging system 15 A (2)Bilge air blower7.5 ANavigation lights3 AGauges supply5 AAuxiliary system10 ARadio10 A12-volt jack10 ANavigation lights3 ABlower7.5 AMain fuses (2)20 AADDITIONAL INFORMATION:12-01-4 LMR2004-028_12_01A.FM

Section 12 TECHNICAL DATASubsection 01 (SPEEDSTER 200)FUEL SYSTEM SPEEDSTER 200Rotax EMS (engine management system)Fuel injection typemultipoint fuel injection.Single throttle body (52 mm (2.05 in))Fuel pressure42 PSI - 45 PSIIdle speed (in water/out of water)1800 ± 50 RPMThrottle Position Sensor (TPS)1.6 kΩ - 2.4 kΩCrankshaft Position Sensor (CPS)5 voltsCamshaft Position Sensor (CAPS)12 voltsCamshaft Position Sensor (CAPS)1.2 kΩManifold Air Temperature Sensor (MATS)2.28 kΩ - 2.74 kΩCoolant Temperature Sensor (CTS)2.28 kΩ - 2.74 kΩExhaust Gas Temperature Sensor (EGT)2.28 kΩ - 2.74 kΩManifold Air Pressure Sensor (MAPS) 0 Ω (continuity between terminals 3 and 1)Knock Sensor (KS)5 MΩOil Pressure Switch (OPS)0 Ω, if oil pressure is greater than 26 - 32 PSIOil Separator Pressure Switch (OSPS)0 Ω, if blow-by pressure is less than 6 PSITOPS valve1.27 Ω - 2.47 ΩFuel injector11.4 Ω - 12.6 ΩRegular unleaded gasoline with 87 octaneTypeFuel(Ron + Mon)/2 specificationMinimum octane no. 87ADDITIONAL INFORMATION:COOLING SPEEDSTER 200TypeLiquid cooled. Closed loop for engine -open loop for exhaust systemEthylene-glycol 50%/50% antifreeze/water.CoolantCoolant containing corrosion inhibitors forinternal combustion aluminum enginesThermostat87°C (188°F)Monitoring beeper setting110°C (230°F)ADDITIONAL INFORMATION:LMR2004-028_12_01A.FM 12-01-5

Section 12 TECHNICAL DATASubsection 01 (SPEEDSTER 200)PROPULSION SPEEDSTER 200Propulsion systemBOMBARDIER Formula pumpNumber of jet pumps 2Jet pump typeAxial flow single stage. Greased bearingsImpeller rotation (seen from rear)CounterclockwiseTransmissionDirect driveCoupling typeCrown splinesReverse systemYesJet pump bearing grease (P/N 293 550 032),Grease type10 mL front bearing, 50 mL rear of bearing,50 mL in pump capSteering nozzle pivoting angle 26°Minimum required water level for jet pumps90 cm (3 ft)Drive shaft deflection (maximum)0.5 mm (.020 in)Impeller outside diameter155.3 ± 0.3 mm (6.122 ± .0118 in)Impeller/wear ring clearanceNew0.0 - 0.4 mm (.000 - .016 in)Wear limit1.0 mm (.040 in)Impeller shaft end play (new) 0Impeller shaft side play0.75 mm (.029 in)Impeller materialStainless steelADDITIONAL INFORMATION: Do not mix different brands or oil types.DIMENSIONS SPEEDSTER 200Number of passenger (driver incl.) 7Overall length6.02 m (237 in)Overall width2.44 m (96 in)Overall height1.42 m (56 in)Dry weight1256.5 kg (2770 lb)Draft30 cm (12 in)Dead rise 20°Load limit (passenger and luggage)635 kg (1400 lb)ADDITIONAL INFORMATION:CAPACITIES SPEEDSTER 200Engine oil3 L (3.2 U.S. qt) oil changew/filter 4.5 L (4.8 U.S. qt) totalCooling system (coolant) 6.65 L (7.03 U.S. qt) total (x 2)Fuel tank (including reserve)151 L (40 U.S. gal)Impeller shaft reservoir capacity80 mL (2.7 U.S. oz)Impeller shaft reservoir oil levelUp to plugADDITIONAL INFORMATION:12-01-6 LMR2004-028_12_01A.FM

Section 12 TECHNICAL DATASubsection 01 (SPEEDSTER 200)MATERIALS SPEEDSTER 200HullCompositeInlet grateAluminumSteering coverThermoplasticImpeller housing/stator/venturi/nozzlePlastic/stainless steel/aluminum/aluminumAir intake silencerN.A.Flame arresterTubular wire screenFuel tankPolyethyleneSeatPolyurethane foamADDITIONAL INFORMATION:PERFORMANCE SPEEDSTER 200Estimated pump power 57 kW (76.44 HP) (x 2)Maximum fuel consumption at wide open throttle 41.1 L/h (10.8 U.S. gal/h)Cruising time at full throttle Fuel tank 117 minutesADDITIONAL INFORMATION:LMR2004-028_12_01A.FM 12-01-7

Section 13Subsection 01WIRING DIAGRAMS(WIRING DIAGRAMS)WIRING DIAGRAMS 0WIRE COLOR CODESFirst color of a wire is the main color. Second coloris the tracer.Example: YELLOW/BLACK (YL-BK) is a YELLOWwire with a BLACK tracer.WIRE DIGIT CODESMPEM and Vehicle Electrical SystemFirst number indicates in which connector thewire is plugged in.Second number indicates the position of the wirein the connector.The letter at the end of the number (if applicable)indicates a common circuit in the MPEM printedcircuit with another wire bearing the same letter.Example: 2-18 (g)The first number indicates that the wire is positionedin the connector no. 2 of the MPEM.The second number indicates that the wire is positionedin the terminal no. 18.The letter (g) indicates a common circuit with anotherwire(s) bearing the same letter (g) in the circuit.DEUTSCH CONNECTORSRemovalTo disconnect two Deutsch connectors, slide a flatscrewdriver between each other to disengage,press the release button and disconnect them.F18Z0LA 21. Flat screwdriver2. Deutsch connectors12EMS ECUOn the EMS ECU, circuits are identified by a letterfollowed by a number.The letter indicates in which connector the wire isplugged in.The number indicates the position of the wire inthe connector.The connector “A” is connected to the engine wiringharness.The connector “B” is connected to the sport boatwiring harness.F18Z0MA 1 21. Release button2. Deutsch connectorsLMR2004_029_13_01A.FM 13-01-1

Section 13 WIRING DIAGRAMSSubsection 01 (WIRING DIAGRAMS)F18Z0NA 2 11. Deutsch connectors2. Press release buttonDeutsch connectors are used to connect wiringharness to the magneto and to the VCK.31V01G0OAFEMALE HOUSING1. Female lock1F00H1CA2431. Male housing2. Female housing3. Secondary lock4. Sealing capCAUTION: Do not apply dielectric grease oncontacts inside plug connector.To remove wire contacts from housing, proceedas follows:– Using a long nose pliers, pull out the lock.V01G0PA 1MALE HOUSING1. Male lockNOTE: Before extraction, push wire forward to relievepressure on retaining tab.– Insert a 4.8 mm (.189 in) wide screwdriver bladeinside the front of the contact cavity.13-01-2 LMR2004_029_13_01A.FM

Section 13Subsection 01WIRING DIAGRAMS(WIRING DIAGRAMS)– Pry back the retaining tab while gently pullingwire back until contact is removed.Deutsch 6 pin Connector Electrical Box111F04H6KAV01G0QAFEMALE CONNECTOR HOUSING1. Retaining tabsTo install:– For insertion of signal contact, make sure thelock is removed.– Insert contact into appropriate circuit cavity andpush as far as it will go.– Pull back on the contact wire to be sure the retentionfingers are holding the contact.– After all required contacts have been inserted,the lock must be installed.16-PIN CONNECTOR1. Wires identification numbersPACKARD CONNECTORPackard connectors are used to connect electricalharnesses and gauges.1CBAF04H45A1 1VIEW OF A 3-POSITION PACKARD CONNECTOR1. Identification lettersTo remove terminal from Packard connector housing,use Snap-on TT600-4 tool.F04H6LAF01B1JA1. Wire identification numbersLMR2004_029_13_01A.FM 13-01-3

Section 13 WIRING DIAGRAMSSubsection 01 (WIRING DIAGRAMS) WARNINGEnsure all terminals are properly crimped onwires and connector housings are properlyfastened.AMP PLUG CONNECTORThese connectors are found on the MPEM.When servicing electrical system, special caremust be taken when working with AMP plug connectorsin order to prevent any malfunction of thesystem.RemovalTo remove the plug connector from the header assembly,press both tabs and pull plug.21Description527194F00H0NAStepStep1 : Press tabs (both sides)2 : Pull plugInstallationApply a thin coat of DEOXIT contact lubricant (P/N293 550 034) to the pins of the header on theMPEM only.3F00H0WB689AMP PLUG CONNECTOR1. Plug assembly2. Cover assembly3. Mating seal4. Wedge lock5. Header assembly6. Seal plug7. Power wire8. Signal wire9. Locking tabF00H11A11. Apply a thin coat of DEOXIT contact lubricantCAUTION: Do not apply lubricant excessively.Care must be taken so that the lubricant will notcome in contact with the mating seal; the sealmay loose its sealing capacities. Do not applylubricant on contacts inside plug connector.13-01-4 LMR2004_029_13_01A.FM

Section 13Subsection 01WIRING DIAGRAMS(WIRING DIAGRAMS)Each plug assembly is mechanically keyed to mateonly with identical mechanical keyed header onthe MPEM.1 2F00H0OA1. Screwdriver between wedge lock and connector2. Locking tabRepeat the same steps for the other locking tabretaining the wedge lock.The wedge lock is now in the open position.F00H12A 111. Mechanically keyedContact RemovalSignal WireInsert a screwdriver blade between the connectorand the wedge lock tab.Release the locking tab and at the same time, pryopen the wedge lock to open position.CAUTION: The wedge lock should never be removedfrom the connector for insertion or removalof the signal wire contacts.F00H0PA1. Wedge lock openedLMR2004_029_13_01A.FM 13-01-5

Section 13 WIRING DIAGRAMSSubsection 01 (WIRING DIAGRAMS)While rotating the wire back and forth over a halfturn (1/4 turn in each direction), gently pull the wireuntil the contact is removed.Before extraction, push wire forward to relievepressure on retaining tab.Insert a 4.8 mm (.189 in) wide screwdriver bladeinside the front of the contact cavity.12F00H0QA1. Rotate wire back and forth2. Pull wirePower Wire ContactNOTE: The wedge lock must be removed to extractpower contact.Open the wedge lock.Pull both locking tabs and remove wedge lockfrom plug assembly.F00H0RA11. Pull locking tab (both sides)F00H0ZAPry back the retaining tab while gently pulling wireback until contact is removed.Contact CrimpingThe size of the wires must be 20 to 16 AWG witha wire insulation diameter having a minimum dimensionof 1.7 mm (.067 in) and a maximum dimensionof 2.78 mm (.106 in).The wire strip length shall be 5.1 mm (13/64 in).NOTE: When stripping wires, ensure conductor isnot nicked, scraped or cut. Wire stripping tool jawsmay leave marks on the surface of the wire insulation.If these marks occur at the location of thewire seal, leakage may result. Insulation surfacewithin 25 mm (1 in) from the tip of the contactmust be smooth.All contacts in AMP plug connectors must becrimped using the crimping tool (P/N 295 100 164).13-01-6 LMR2004_029_13_01A.FM

Section 13Subsection 01WIRING DIAGRAMS(WIRING DIAGRAMS)CAUTION: If contacts are not crimped usingthe proper crimping tool, the wire seal may bedamaged.F00B0EACRIMPING TOOL (P/N 295 100 164)All circuits are sealed by a diaphragm in the rubberwire seal. When installing wire contacts in plugconnector, the diaphragm is pierced as the contactpasses through it.If the diaphragm is pierced and the cavity is notused, install a seal plug, large end first, into circuitcavity as far as it will go.NOTE: It is suggested that all unused circuit cavitiesbe sealed with a seal plug, even if they are notpierced.1CAUTION: Do not pierce the diaphragm with asharp point for electrical troubleshooting. Theresulting pinholes in the insulation will allowmoisture to penetrate the system and possiblyresult in system failure.Contact InstallationFor insertion of signal contact, make sure thewedge lock is in the open position.NOTE: For insertion of power contact, the wedgelock may or may not be on the open position.Insert contact into appropriate circuit cavity andpush as far as it will go.Pull back on the contact wire to be sure the retentionfingers in the housing are holding the contactproperly.After all required contacts have been inserted, thewedge lock must be closed to its locked position.IDENTIFICATION OFCONNECTOR PINSAMP Connectors of MPEM26 25 24231581691F04H6RAF00H10A21. Seal plug2. Wire sealLMR2004_029_13_01A.FM 13-01-7

Section 13 WIRING DIAGRAMSSubsection 01 (WIRING DIAGRAMS)AMP Connectors of Wiring HarnessCrimping and Installation ToolsRequiredTo install EMS ECU connector terminal pins or terminalwire, three tools are required; EMS ECUcrimping tool, EMS ECU extraction tool and a standardflat screwdriver.932F04H6GAEMS ECU CONNECTORSThere are two EMS ECU connectors used on the4-TEC models and they are connected on the EMSECU. The engine harness female connector is connectedon the module male connector “A” and thesport boat system control harness female connectoris connected to the module male connector“B”. The engine connector has 41 pins.F18Z03A1. EMS ECU crimping tool2. EMS ECU connector terminal extraction tool3. Standard flat screwdriverDefective Terminal RemovalUnlock the terminal cover by disengaging the terminalcover locking device on both side with a flatscrewdriver.132211F18Z02A1. EMS ECU2. A connector (engine harness)3. B connector (sport boat system harness)F18Z04A1. Terminal connector cover2. Terminal cover locking device13-01-8 LMR2004_029_13_01A.FM

Section 13Subsection 01WIRING DIAGRAMS(WIRING DIAGRAMS)1Lift wire harness and note the terminal pinout number.The EMS ECU connector has 41 terminals.The pins are split into three groups; 1 to 13, 14 to28 and 29 to 41. Make sure you have located theproper terminal.21F18Z05A1. Terminal connector cover2. Terminal cover locking deviceLift the cover by pushing it forward.2F18Z08A11. Wire harness2. Terminal pinout numbersOnce the defective terminal is identified, unlockthe red terminal locking plate by using the flatscrewdriver and release the locking device at eachend of the connector. Remove the red terminallocking plate by sliding it outside the connector.F18Z06A1. CoverCut both locking ties.211F18Z09A1. First locking device2. Red terminal locking plateF18Z07A1. Locking tiesLMR2004_029_13_01A.FM 13-01-9

Section 13 WIRING DIAGRAMSSubsection 01 (WIRING DIAGRAMS)Release the defective terminal from connectorwith the extraction tool. Align the extraction toolpin properly with the terminal cavity and push thetool downward. That will release the wire with theterminal.122F18Z0AA1. Second locking device2. Red terminal locking plate13F18Z0DA11. Terminal cavity2. Extraction tool3. Extraction tool pinF18Z0BA1. Red terminal locking plateRemove the red terminal locking plate and acquirethe EMS ECU extraction tool.212F18Z0EA1. Extraction tool2. Connector terminal housingF18Z0CA11. Red terminal locking plate2. EMS ECU extraction tool13-01-10 LMR2004_029_13_01A.FM

Section 13Subsection 01WIRING DIAGRAMS(WIRING DIAGRAMS)123F18Z0HAF18Z0FA1. Connector terminal housing2. Defective wire and terminalIf the wire is in good condition but the terminal isrusted or corroded, remove defective terminal andcrimped a new one. If wire and terminal are defective,acquire a new genuine wire and new terminaland crimp them together as follow.IMPORTANT: Use genuine wires only. Otherwisewires will not fit properly.Terminal and Wire Crimping2To crimp a new terminal to a good wire, acquirethe EMS ECU crimping tool. Install the new terminalin the crimping tool swivel. Close the swivel inplace. Place the wire on terminal barrel and crimpthe wire firmly.11. Crimping tool swivel2. Crimping tool3. WireCAUTION: Probe on top of terminal only. Donot try to probe inside terminal or to use a paperclip to probe inside terminal, it can damagethe square-shaped terminal.CAUTION: Do not disconnect the EMS ECUconnector needlessly. They are not designed tobe disconnected/reconnected frequently.LubricationApply a thin coat of DEOXIT contact lubricant (P/N293 550 034) to the pins of the header on the EMSECU only.2 31F18Z0GA1. New terminal2. Crimping tool swivel3. Crimping toolLMR2004_029_13_01A.FM 13-01-11

2004 SPEEDSTER 200AVERTISSEURPorte-fusibles du moteurALIMENTATIONEN ESSENCEPorte-fusibles du moteurMOTEURGAUCHEMOTEURDROITInterface desINDICATEURSHAUT-PARLEURBABORDARRIÈREHAUT-PARLEURTRIBORDARRIÈREVitesseInterrupteurde DESSMassedu DESSAVERTISSEUR – Batt. faibleSignaldu DESSVérif. moteurLigne de comm.(HAUT)TempératureélevéeLigne de comm.(BAS)Bas niveaud’huileMasseInterrupteurde DESSTr/mnSignaldu DESSBatt. faible Vérif. moteurTempératureélevéeLigne de comm. Ligne de comm.(HAUT) (BAS) MasseBas niveaud’huileInterrupteurde DESSSignaldu DESSTr/mnALIMENTATIONDESINDICATEURSALIMENTATIONDESINDICATEURSVOYANTSInterrupteurde DESSPorte-fusibles du moteur gauchePorte-fusibles du moteur droitTACHYMÈTREBLOC DE JONCTIONVOYANTSFEU DE PONTTACHYMÈTREFEUDE PONTFEUDE PONTFEUDE PONTINDICATEURDE VITESSEINDICTEURDE NIVEAUD’ESSENCE/HUILEINTERRUPTEURDÉMARRAGE/ARRÊT(GAUCHE)INTERRUPTEURDÉMARRAGE/ARRÊT(DROIT)INTERRUPTEURDE POINT MORT(GAUCHE)FEUFEUALIMENTATIONDISP. NETTOYAGEGRILLESD’ADM. D’EAUCOMMANDEDISP. NETTOYAGEGRILLESD’ADM. D’EAUINTERRUPTEURDISP. NETTOYAGEGRILLES D’ADM. D’EAUINTERRUPTEURDE POINT MORT(DROIT)F13Z02

2004 SPEEDSTER 200INTERRUPTEURDE DÉMARRAGERELAIS DEDÉMARREURvers le relais de démarreurvoir page 1interface des indicateursINTERRUPTEURDE POINT MORTPOMPE ÀESSENCECONNECTEUR DEDIAGNOSTICSOUPAPEDE RALENTIBOBINE 1 BOBINE 2 BOBINE 3 CPAC ANTI-RETOUR STA CPA STE STGESPHSPHDÉTECTEURDE DÉTONATIONSPACPVPORTE-FUSIBLESINTERRUPTEUR DE DESSALIMENTATION DES INDICATEURSINTERFACEMASSEMASSEDU PORTE-FUSIBLESINTERFACELIGNE DECOMM. (BAS)INTERFACELIGNE DECOMM. (HAUT)RELAIS DEDÉMARREURDU SGM –RELAIS DEDÉMARREUR –RELAIS DEDÉMARREUR +POMPE ÀESSENCEDIAGNOSTICMASSEDIAGNOSTICLIGNE DECOMM. (BAS)DIAGNOSTICLIGNE DECOMM. (HAUT)LIGNE KSGMSGMDÉMARRAGE/ARRÊTRELAIS –SGMMONITEURDE DESSSOUPAPEANTI-RETOURBOBINESCYLINDRE 3BOBINESCYLINDRE 2BOBINESCYLINDRE 1MASSESOUPAPE DE RALENTI AMASSESOUPAPE DE RALENTI BMASSESOUPAPE DE RALENTI CMASSESOUPAPE DE RALENTI DINJECTEUR 1 –BOBINE 1 –INJECTEUR 2 –BOBINE 2 –INJECTEUR 3 –BOBINE 3 –SIGNAL CPACCPAC –ANTI-RETOUR –SPH RÉSERVOIRSTA –STA +SIGNAL DU CPACPA +CPA –STE –STE +STGE –STGE +SYSTÈME DE GESTION DU MOTEURSPH MOTEURDÉTECTEUR DEDÉTONATION –DÉTECTEUR DEDÉTONATION +SIGNAL DE LA SPAMAPS +MAPS –CPV +CPV –INTERRUPTEURDE DESSMASSEDE DESSALIMENTATION DEL’ACCUMULATEURRELAIS –DÉMARRAGE/ARRÊTLIGNE DECOMM. (BAS)LIGNE DECOMM. (HAUT)LIGNE KPOMPE À ESSENCERELAIS DE DÉMARREURSIGNAL DU DESSPORTE-FUSIBLES DU MOTEURMASSEDU MOTEURMASSEDU MOTEURMASSEDU MOTEURF13Z03